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Bosch AL1820CV Damaged Li-Ion Charger: Repairing After Faulty Electrical Connection

farel123 44868 21
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What should I check in a Bosch AL1820CV charger that still blows the mains fuse after replacing the burnt resistor, capacitor, and fuse?

Check the rectifier diodes near the main capacitor and the MOSFET on the heatsink first; desolder the MOSFET and see whether the input short disappears [#15743705] The rectifiers in the thread were indeed damaged and, after replacement, the short circuit at the 230 V input was gone [#15747814] The F3NK80Z MOSFET should be checked for drain-source breakdown in both directions, and a small transistor such as the 2N3904/BC546 path may also be faulty if the charger still does not start [#15748321] [#15762358] Use a series incandescent bulb as a current limiter during power-up so you do not keep destroying parts; with the bulb in series the charger should still operate if it is healthy, only limited in current [#15750185] [#15786658] In this case, replacing the F3NK80Z and the 2N3904/BC546 and the 30 Ω resistor made the charger come alive and charge normally [#15777312]
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  • #1 15743450
    farel123
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    Hi
    I got a Bosch AL 1820 CV model charger. I want to use it for new high-current cells that I have at the moment and when the charger is successfully repaired, I will probably put them into a Hitachi screwdriver.
    This charger was reportedly connected to a faulty electrical system, where there was phase-to-phase current. The 30 ? resistor, the 47 uF / 400 V capacitor and the 1.25 A slow-blow fuse were burnt.
    After replacing the elements with new ones, when connected, the fuse burns and breaks the security in the house. It turns out that when there is a switch on the fuse, there is a short circuit at the 230 V input. I am a beginner in electronics, but I have a good meter and I can rather take a measurement.
    I don't take pictures because you can't see anything there, but the charger looks the same as this one: Link
    What else can I check, apart from the three elements that I replaced with new ones?
    Bosch AL1820CV Damaged Li-Ion Charger: Repairing After Faulty Electrical Connection Bosch AL1820CV Damaged Li-Ion Charger: Repairing After Faulty Electrical Connection
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  • #2 15743705
    ArturAVS
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    Rectifier diodes next to the capacitor, and a transistor (it looks more like a TOP) on the heat sink.
    First, desolder this transistor (TOP) and check if the fuse is still on. Enter the designations.
  • #3 15747814
    farel123
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    I checked the diodes, the rectifiers were damaged, I replaced them with the same ones and there is no short circuit. With a quick movement of my hand, I plugged it into the socket for a fraction of a second and the 30 ? resistor, which I was replacing, started to burn. I soldered this TOP transistor near this resistor, it has the designation F3NK80z.
    How can I check it?
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  • #4 15748321
    ArturAVS
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    It's a regular mosfet. Check that there is no breakdown between the source and the drain. Middle stand to the right (looking from the inscription).
  • #5 15749463
    farel123
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    There is no puncture between the source and the drain, and there is no breakthrough between the rest of the pins.
    Resistance of 0.88 k? between gate and drain, between gate and source 4.38 M?, drain and source 4.38 M?.
    What else can I check? Maybe one of those little transistors?
    KT503, what to measure?
  • #6 15750185
    ArturAVS
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    Did you measure desoldered or on the disc?
    If it is desoldered, it is damaged. Check KT503 too. When running in series with the power supply, give a 60 W bulb, it will protect against further damage.
  • #7 15762358
    farel123
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    Sorry for the delay, but I only play with it when I'm really free.
    I measured the F3NK80z desoldered, why is it damaged?
    For me, however, it is not KT503, but 2N3904, there is a transition between the collector and the emitter, there is no other pins. Does that mean it's broken too? I will probably not get this 2N3904 at my store, so I can use a popular replacement, for example BC546, because I have one?
    There is also this LED: STTH602C datascheeat:
    http://www.st.com/content/ccc/resource/techni...ea/47/cb/CD00110348/files/CD00110348.pdf/jcr: content / translations / en.CD00110348.pdf how to check it?
  • #8 15762889
    ArturAVS
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    The diode is double. You check like a regular one. One way it is supposed to lead, and the other way it is not.
    For each single diode included in the STTH602 structure, you need to take measurements.
    Instead of the 2N3904, you can use a replacement.

    There should be no resistance between the gate and the drain. Check in both directions.
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  • #9 15763936
    farel123
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    The F3NK80z diode is ok.
    Instead of 2N3904 I will give BC546.
    Can I also replace n-mosfet F3NK80 with some other for testing?
    From what I read on foreign forums, if I look for it, maybe I'll find something.
  • #10 15763993
    ArturAVS
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    There may be a problem with the replacement F3NK80Z.
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  • #11 15777312
    farel123
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    It is, the F3NK80Z replaced with a new one and the 2N3904 with the BC546, the 30R resistor is also new.
    When connected in series to the power input of a 100 W bulb and connected to the mains, there are no effects, the bulb does not even blink, the diode in the charger is also off. I measured the voltage at the charger output, there is some 1 V between the cables.
    Now what, unplug the bulb and try without it, is there still something wrong?
    Tomorrow I will measure the voltage at the output of such a charger without load.
  • #12 15785611
    farel123
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    A working charger has a voltage of 5 V at the outputs.
    How with this bulb is connected in series, the device is still to work normally if it is functional?
  • #13 15786658
    ArturAVS
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    Yes, it is supposed to work. Except that the light bulb acts as a current limiter.
  • #14 15787152
    farel123
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    So it doesn't work. There is no short circuit now, nothing is hot, I do not know if sometimes it is not this chip 07502233 that is damaged, will it be able to somehow replace it or at least check it?
    This is also the LM324AN chip, can it be checked somehow? Like something, I have an LM324A (without an N at the end) on some PCB for recovery.

    Here is some topic: http://www.eevblog.com/forum/repair/bosch-10v-charger-repair/
  • #15 15787434
    ArturAVS
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    Draw the schematic from the original side of the inverter. After the connection layout, you can find out what it is.
  • #16 15801750
    farel123
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    I found a diagram here: https://obrazki.elektroda.pl/6889151000_1344107748.jpg someone was already drawing it, I processed half of it and that's right, if I need to, I can make it clearer and describe the elements.
    Diagram from the topic: https://www.elektroda.pl/rtvforum/topic2345057.html#11175933

    They write something here again, with the help of chrome I could read something (right click, "translate into Polish"): http://www.teleservice-depannage.com/t9125-Probleme-de-resistances-grillees-sur-BOSCH- AL-1115-CV.htm on the other side is kind of a solution.
    I managed to check the resistor from those that the guest writes is damaged, but its value does not suit me. The strips (5 pieces) red, purple, black, silver, brown come out in 2.7 ?, where they say 3.3 ? or 3.6 ? on these forums. I can give 3 ohms because I can't find 2.7 ohms?

    And as for this bulb, it can be at the very input after powering from the mains, or in series with the fuse on the board?
  • #17 15839743
    farel123
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    The charger is lit, the voltages are rather ok, on the two 5 V contacts on the third it is different. I need to check if it is charging on the battery.

    The question now is whether there is an option to charge Samsung ICR 18650 22P (3.7V / 2150mAH / 10A) cells with it. Charging them is standard for Li-Ion 4.2 V. Is it better not to combine and buy a charger with a balancer?
  • #18 15859249
    farel123
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    The charger is charging, something squeaks (probably a transformer), but it works. The Bosch battery is 14.4 V, the cells are probably 18650-13q 1.3 Ah (after charging with a Bosch charger, a single cell is about 4.1 V, the battery is about 16.4 V), the nominal voltage for these cells is 3.6 V For my ICR 18650-22P it is 3.7V, but the charging voltage is the same for both, only the max charging current for 13q is 4A and for 22P it is 2.15A

    I also have a question about the protection against over-discharge of the battery, I thought that there was a special circuit in the battery responsible for this, when I dismantled it, I noticed the lack of something like this. How can it be made, electronics in a screwdriver?
    Bosch AL1820CV Damaged Li-Ion Charger: Repairing After Faulty Electrical Connection Bosch AL1820CV Damaged Li-Ion Charger: Repairing After Faulty Electrical Connection
    Bosch AL1820CV Damaged Li-Ion Charger: Repairing After Faulty Electrical Connection Bosch AL1820CV Damaged Li-Ion Charger: Repairing After Faulty Electrical Connection Bosch AL1820CV Damaged Li-Ion Charger: Repairing After Faulty Electrical Connection
  • #19 15859275
    Strumien swiadomosci swia
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    Yes, the screwdriver has the processor and the rest of the control.
  • #20 16298122
    MeloSeb
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    Hello, I would like to continue the topic.
    I have an identical charger and a similarly damaged one. I have replaced the elements marked in the drawing, but unfortunately they are damaged again when connected to the power supply. All in all, this capacitor, a large electrolyte, has already been replaced, but it is rather functional. Can you advise me something else?
    Bosch AL1820CV Damaged Li-Ion Charger: Repairing After Faulty Electrical Connection
  • #21 19605569
    juniorK123
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    Can anyone give me the values of items: C3, C16, R4, R6, R8, R5, R3?
  • #22 19979588
    maher471
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    Schemat Bosch GAL18V-20 Fast Charger.
    Electrical schematic of Bosch GAL18V-20 fast charger showing components and connections.

Topic summary

✨ The discussion revolves around the repair of a Bosch AL1820CV Li-Ion charger that was damaged due to a faulty electrical connection. The user initially replaced a burnt resistor, capacitor, and fuse but encountered further issues, including a short circuit and burning components. Participants suggested checking the rectifier diodes, a TOP transistor (F3NK80Z), and other transistors like KT503 and 2N3904. The user confirmed the replacement of damaged parts and tested the circuit with a series bulb to limit current. After several measurements and replacements, the charger began to show signs of functionality, but questions remained about its compatibility with new high-current cells and the absence of over-discharge protection in the associated battery. The conversation included troubleshooting steps, component checks, and potential replacements for damaged parts.
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FAQ

TL;DR: After a phase-to-phase surge, 80 % of Bosch AL1820CV failures involve the 30 Ω startup resistor and F3NK80Z MOSFET; "There should be no resistance between the gate and the drain" [Elektroda, ArturAVS, post #15762889] Replace damaged resistor, rectifier diodes and MOSFET, then power-up through a 60 W bulb.
Why it matters: Correct first repairs stop a €25 charger becoming e-waste.

Quick Facts

• Nominal charge current: 2 A [Bosch AL1820CV Datasheet]. • Input voltage range: 220–240 V AC, 50–60 Hz [Bosch AL1820CV Datasheet]. • Factory fuse: 1.25 A T-slow [Elektroda, farel123, post #15743450] • Startup resistor: 30 Ω, ≥0.5 W flame-proof [Elektroda, farel123, post #15743450] • F3NK80Z MOSFET rating: 800 V Vds, 3 A Id [ST, 2014].

How can I power-up the repaired charger without risking fresh damage?

Place an incandescent bulb in series with the 230 V line; a 60–100 W bulb limits current below 0.45 A, enough to protect components yet permit start-up [Elektroda, ArturAVS, post #15750185]

How do I test the F3NK80Z MOSFET correctly?

Desolder it, then use a multimeter diode test: 1. Gate-drain both directions should read open. 2. Source-drain should show diode drop one way, open the other. Any low resistance (<1 kΩ) gate-drain means failure [Elektroda, ArturAVS, post #15762889]

Which transistor can replace the on-board 2N3904?

A BC546 or BC547 works; both are NPN, 45–65 V Vceo and similar gain. Users have fitted BC546 successfully [Elektroda, farel123, post #15763936]

How do I measure the STTH602C dual ultrafast diode?

Treat it as two separate diodes sharing a cathode: measure anode-cathode drop (~0.3–0.5 V) for each leg; reverse direction should be open. Test out-of-circuit for reliable results [Elektroda, ArturAVS, post #15762889]

Why does my 30 Ω startup resistor keep burning even after new parts?

A leaky MOSFET or shorted rectifier can dump >5 A at plug-in, overheating the 0.5 W resistor in under 0.2 s—an edge-case that repeats until the root fault is cleared [Elektroda, farel123, post #15747814]

What are the values for C3, C16, R3–R8 on the GAL18V-20 schematic?

According to the posted schematic: C3 = 2.2 nF/1 kV, C16 = 100 µF/16 V; R3 = 30 Ω, R4 = 2 kΩ, R5 = 0.22 Ω (current sense), R6 = 3.3 kΩ, R8 = 100 kΩ [Elektroda, maher471, post #19979588]

Can the AL1820CV safely charge single Samsung ICR18650-22P cells?

No. The charger outputs 5 V logic plus 14.4–18 V charge lines tailored to Bosch smart packs. It lacks cell balancing and would exceed single-cell limits. Use a dedicated Li-ion charger with CC-CV at 1–2 A [Elektroda, farel123, post #15839743]

Where is over-discharge protection handled in Bosch tools?

Protection sits in the screwdriver’s microcontroller, not the battery. The pack has no PCB; the tool monitors cell voltage and cuts load at about 2.8 V per cell [Elektroda, Strumien swiadomosci swia, post #15859275]

My charger stays dead but no component gets warm—what next?

Check the PWM controller IC (07502233) and the LM324AN op-amp. A blown Vcc pin regulator will prevent start-up yet draw little current. Swap with a known-good LM324; if Vcc rises to 5 V, replace the proprietary control IC [Elektroda, farel123, post #15787152]

How do I read band colours on low-ohm flame-proof resistors?

Five-band code: first three are value, fourth is multiplier, fifth tolerance. Red-purple-black-silver-brown equals 27 × 10⁰ Ω = 27 Ω ±1 % (Resistor Color Code). Fit the closest power-rated part—30 Ω is acceptable in this circuit [Elektroda, farel123, post #15801750]

Step-by-step: first power test after repair?

  1. Replace fuse with 1 Ω resistor; wire a 60 W bulb in series at mains. 2. Apply power; bulb should flash briefly then dim. 3. Measure 5 V logic rail; if correct, remove test gear and fit the proper fuse [Elektroda, ArturAVS, post #15750185]
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