Re-wire a battery charger

Discussion in 'The Projects Forum' started by Gdrumm, Aug 9, 2011.

  1. Gdrumm

    Thread Starter Distinguished Member

    Aug 29, 2008
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    Someone threw away a Schumacher SE-2151MA car battery charger, that had been stripped down a bit.

    I would like to re-wire it and test it.

    I have a schematic from a different charger, but it is too dissimilar to help.

    Please look at attached photos, and see if you can give me any insights.

    The Rate Switch has 10 posts, and is a 4 way switch.
    Left side is 15A 6v, the middle two are 2A and 15A 12 V Auto, the far right is 100 A 12 V Engine Start.

    I've Googled for a schematic and cannot find one.

    This is a low priority project...

    Thanks,
    Gary
     
  2. iONic

    AAC Fanatic!

    Nov 16, 2007
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    That's one mean power hungry machine!
     
  3. SgtWookie

    Expert

    Jul 17, 2007
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  4. Gdrumm

    Thread Starter Distinguished Member

    Aug 29, 2008
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    I contacted Schumacher, and suprisingly (to me anyway) they are going to mail the complete parts list and schematic.

    I'll post back with pictures, when I get them.

    Gary
     
  5. Gdrumm

    Thread Starter Distinguished Member

    Aug 29, 2008
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    Here is the schematic Schumacher sent me.

    Gary
     
  6. SgtWookie

    Expert

    Jul 17, 2007
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    Looks to me like the 100A rectifier assembly is missing.
    [eta]
    Wait a minute, the above was wrong - the 4-position selector switch isn't connected, looks like this:
    http://www.centurytool.net/0499000070_Schumacher_4_Position_Slide_Switch_p/0499000070.htm

    In your 2nd picture, the back of the 4-position switch is shown on the left; blue and black wires connected to it. Most of the connections are disconnected; it should be wired like the schematic - but there is no blue wire in the schematic.
    The blue wire must be what's labeled "BLK (463) 2" in the schematic.

    Check to see if the switch is working properly.
     
    Last edited: Aug 16, 2011
  7. Gdrumm

    Thread Starter Distinguished Member

    Aug 29, 2008
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    Yes,
    I agree, the blue in my picture 1, is right beside the yellow, which would be black 2 in the schematic.

    I'll wire it up this evening, and post back.

    Thanks,
    Gary
     
  8. SgtWookie

    Expert

    Jul 17, 2007
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    You should test the switch to make sure that all of the contacts are working.
     
  9. Gdrumm

    Thread Starter Distinguished Member

    Aug 29, 2008
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    I tried wiring it this afternoon only to discover that mine has a different transformer. Mine has 4 input pairs (1-2,3-4,5-6,7-8), and the schematic shows 5 input pairs (1-2,3-4,5-6,7-8,9-10), so as far as I can tell, they are totally different. I emailed Schumaker with what appears to be a part number on the top of my transformer, perhaps they will have something.

    On my transformer, (left to right):
    (first pair) 1 is empty, 2 has a single black wire
    (second) 3 is blue, and 4 is yellow
    (third) 5 is orange and 6 is black
    (fourth) 7 and 8 are jumpered together with heavy gauge black wire (looks factory)

    Schematic (left to right)
    (first pair) 1 is yellow, 2 is blk 2
    (second) 3 and 4 are jumpered blk
    (third) 5 and 6 are jumpered orange
    (fourth) 7 and 8 look dead
    (fifth) 9 is open, and 10 black (incoming 110v hot wire)

    I will draw them out side by side, but for now, I think they are too different.

    I'll post back.

    Gary
     
    Last edited: Aug 16, 2011
  10. Gdrumm

    Thread Starter Distinguished Member

    Aug 29, 2008
    684
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    Schumacher said that they don't have the other schematic.

    Please see my drawing, and let me know if anything seems obvious (as a comparrison between the two transformers)

    I haven't tested the switch yet, but would like to figure out how to hook up the loose wires on my unit.

    Boxes labeled 1t, 2t, 3t, etc., are the switch, top row, -vs- 1b, 2b, 3b btm. row, (pins 1,2,3,4,5 etc.).

    Thanks,
    Gary
     
    Last edited: Aug 17, 2011
  11. Gdrumm

    Thread Starter Distinguished Member

    Aug 29, 2008
    684
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    I found another wiring diagram for a 4 post transformer, same hodel #.
    Tried that, but it popped and smoked at 100 A setting, so I quickly shut it off.

    At least the switch tested good.

    I guess I'll salvage the few good parts, and scrap the rest.

    Thanks for your input.

    Gary
     
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