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Crystalyte charger mod

Old 03-06-09, 10:45 AM
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Crystalyte charger mod

I got my 408 crystalyte kit last month. With 36VDC battery pack and 36VDC 2.5AMP charger. Plugged the charger in last night after a 30 mile trip. Then went to the drug store to get my energy drink, got back plugged the charger back in, no fan. So I unplugged and plugged back in, that let the smoke out. blown fuse, shorted diode. Now this is a 2000PIV bridge circuit at 1.5 amps and 50 amp surge. I had to replace this stuff so I figured: mod. is a good thing.

Some old TV's that are now obsolete because of the HDTV law, and I got these curb side shopping.
From a Deawoo I took out the line filter choke and installed it in place of the 2 jumpers they had in the charger. Perfect fit too. I took out the MOV surge protector from the Deawoo and put it in charger pcb where there used to be a capacitor. I had to stretch the leads to make the MOV fit.
From a Philips TV I took out a fuse holder and installed that for the hard wired fuse that blew, now I had a plug in fuse. Really tight fit.
I replace the 4 diode bridge circuit in the charger, with a single unit bridge from the Philips TV. Lot of lead bending to get this bridge into the charger PCB.

The fan circuit in the charger got fried also, there was a 91 ohm 2 watt resistor that cracked. I couldn't tell what value it was so I measured both good halves. 44 ohms + 47 ohms = 91 ohms. The diode supplying power to the fan was cooked but still good, I jumped the diode with a higher amperage 3A 1000PIV high speed diode.
I replaced the 91 ohm 2 watt with 11 pcs of a 1000 ohm 1/4 watt resistor, value of these are 91 ohm 2.75 watts in parallel.
Fired it up and charged really good, fan resistor, is only consuming 1 watt, fan voltage is 10VDC on a 12 VDC rated fan.

Before this mod to the charger I'd plug it into a GFI and it would kick out the breaker in the GFI

I just found out the the charger no longer kicks out my ground fault interupter.


Last edited by raypsi; 03-06-09 at 01:22 PM.
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Old 03-06-09, 02:37 PM
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it's nice to see im not the only one that recycles part's
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