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Tool Talk Discussion Forum

Battery Charger Booster Failure

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raytasch

01-09-2004 16:15:31




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My Sears charger booster, model 937-718460 has failed. I've traced the problem to the small diodes that are used to make up the rectifier circuit. These 8 diodes are about 1/2" diameter, 1/4" high and held between a common output plate and an insulator. Anyone have any idea who might have made this unit. Sears parts site indicates the rectifiers are not available. Better yet, any idea where I might be able to pick up these diodes.
ray

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Bob

01-10-2004 14:33:10




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 Re: Battery Charger Booster Failure in reply to raytasch, 01-09-2004 16:15:31  
I believe the diodes you are referring to are called "pellet" diodes, and while I don't know of a source for new ones, I have repaired a number of battery chargers by salvaging the "pellet" diodes out of the rectifier heat sinks from Delco internally regulated alternators. Often, one of the 6 diodes fails, and the whole assembly is replaced, leaving 5 good diodes chucked in the trash.

There are 2 finned heat sinks held together with a dovetailed insulator. Remove the insulator, and heat one of the heat sinks quickly with a propane torch until the solder holding the diodes to the aluminum softens, and the diodes can be "flicked" off the heat sink. Have them drop off on a wet rag and quickly cool them so they are not ruined internally. Unsolder the copper straps from the other side of each diode, again working quickly, and keeping the actual diode as cool as possible. The diodes are the same on the positive and negative half of the rectifier, it is just a matter of what direction they were soldered to the aluminum heat sinks. Often, but not always, the diodes are marked with a band on the cathode end.

Carefully sand off any excess solder from the contact pads on the diodes, and test them. You may "kill" some from the unsoldering process, but the majority will work just fine.

You will, of course, have to test them, and mark them, or at least be sure to keep track of which end is which, and install them in the clamp plate mechanism in the proper electrical orientation.

Presto... a "free" repair for your charger.

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raytasch

01-10-2004 17:01:07




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 Re: Re: Battery Charger Booster Failure in reply to Bob, 01-10-2004 14:33:10  
Many thanks for the directions and name of the "pellet" diode. I have a local old time generator alternator shop nearby and my guess is those old boys buy those diodes by the handfull. I'll stop by there on Monday and see what I can find. I'll get back with you on the rectifier assembly if I can not find the diodes. Thanks again. ray



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Bob

01-10-2004 18:08:59




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 Re: Re: Re: Battery Charger Booster Failure in reply to raytasch, 01-10-2004 17:01:07  
Am not absolutely sure of the term "pellet" diode, but that name comes to mind from several years ago when I was looking for a source for these. The local alternator shop most likely will not have the little diodes loose, but will most likely have a bunch of the defective Delco rectifier assemblies.

I used to buy the complete rectifier assemblies for chargers from Century Electric/Solar in Minneapolis, but I understand they sold out. I have not tracked down the new company, yet.

Older chargers used to use selenium plate rectifiers. These had a higher forward voltage drop than silicon diodes, and some transition era chargers had a rectifier made up of a bunch of these "pellet" diodes in parallel between two plates, and then stacked 2 assemblies to put them in series. The 2 silicon junctions in series approximates the forward voltage drop of a selenium rectifier, allowing the use of more modern silcon rectifier with a transformer wound to accomdate the higher voltage drop of the selenium rectifier.

Are your diodes in parallel only (for the needed amperage), or are the assemblies of plates stacked for the series connection, also?

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Bob

01-10-2004 14:37:11




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 Re: Re: Battery Charger Booster Failure in reply to Bob, 01-10-2004 14:33:10  
P.S.

I have several of the complete rectifier assemblies on hand, if repair does not succeed.



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rhudson

01-10-2004 12:50:11




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 Re: Battery Charger Booster Failure in reply to raytasch, 01-09-2004 16:15:31  
i have replaced them with big surplus diodes i had laying around the shop. as long as the operating voltage is around 60 volts or higher and the current capability is higher than your charger claims to be it will work great. i used diodes that i had purchased from surplus center i think they were about 150 amps and cost under $5.00 ea. most battery chargers use a center tapped transformer with two diodes.

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Jon H

01-09-2004 19:16:44




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 Re: Battery Charger Booster Failure in reply to raytasch, 01-09-2004 16:15:31  
Be sure those diodes are bad(open or shorted) before you replace them. Many chargers use a very cheap setup with the button diodes clamped between a couple of steel or aluminum plates to serve as connector and heat sink. Any moisture getting between button and connector plate,especially with aluminum plates will cause corrosion at the button contacts. Have brought many of them back to life with only a cleaning of the connections.

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rjc

01-09-2004 19:15:35




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 Re: Battery Charger Booster Failure in reply to raytasch, 01-09-2004 16:15:31  
I have several cross references and catalogs. Email me with the numbers on the diodes and I will see if I can cross them for you.



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raytasch

01-10-2004 06:06:21




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 Re: Re: Battery Charger Booster Failure in reply to rjc, 01-09-2004 19:15:35  
Appreciate the come back guys but there are no numbers on the diodes. Yep, couple of them are open. If I can find a set of 8 of the same spec diodes with high enough current capacity I am sure they will work.
ray



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Hermit

01-09-2004 17:57:08




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 Re: Battery Charger Booster Failure in reply to raytasch, 01-09-2004 16:15:31  
If you can read the part number off the rectifiers, check the electronic parts websites. One of them should have the part or be able to cross to a substitute.



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raytasch

01-09-2004 17:42:30




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 Re: Battery Charger Booster Failure in reply to raytasch, 01-09-2004 16:15:31  
Should have mentioned this is a roll around floor model rated at 40 amp charge and 225 amp starting boost.
ray



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