drawson said:
Phil
Do you think the charger could have caused the failure in the car. A friend pointed out that the dealer was able to hand the car over with a full charge, and I saw the blue light blinking after I started charging, and then the failure occurred. That would indicate a problem in the charger. Any thoughts?
What will Nissan's position be with me if the charger is causing the problem and damaging the charging system in the car?
I seriously doubt it. First off, let's get the terminology correct: The "charger" is in the car. It's the big box located under the "hump" between the rear seat and the cargo area. It is liquid cooled and based on my observations, very well made:
The thing you are calling the "charger" is in fact the EVSE. This supplies AC power to the charger. The broken "magnet" the dealer supposedly found would have to be located in the actual on-board charger unit, not the inverter, as the inverter has nothing to do with charging operations. The EVSE delivers AC to the charger, which converts it into about 400V DC to charge the Lithium-Ion battery pack. The inverter takes the ~400V DC from the battery and makes 3-phase AC to power the synchronous drive motor.
Furthermore, a broken "magnet", if this is to be even interpreted loosely would mean a physical defect, as there are no moving parts inside the on-board charger unit. (or in the inverter, for that matter!)
Usually solid-state electronics either fail right away (defect) or after many years (accumulated thermal stress, dielectric breakdown, etc). You don't typically see many failures in the "middle" in properly engineered electronics. This to me, seems like a defect in materials, and you just happened to be unlucky enough to find it.
-Phil