nlspace
Posts: 337
Joined: Mon Jun 05, 2017 10:21 pm
Delivery Date: 06 Jun 2017

Re: Onboard charger capacitors failed

Fri Feb 19, 2021 7:17 am

You should probably check the diode drops of the waffle plate to make sure that it is not shorted/damaged, especially the AC rectifier section and the PFC.

With all the damage on the AC input side it is puzzling what might have caused this, similar to wxmatt's damage.

Who1981
Posts: 6
Joined: Sun Feb 07, 2021 12:36 pm
Delivery Date: 05 Feb 2021
Leaf Number: 021208

Re: Onboard charger capacitors failed

Mon Feb 22, 2021 12:14 pm

Thanks, I check the waffle. I don't hold much hope for reviving this board...
Any tips for freeing the toasted capacitors from the potting material, without damaging the board?

nlspace
Posts: 337
Joined: Mon Jun 05, 2017 10:21 pm
Delivery Date: 06 Jun 2017

Re: Onboard charger capacitors failed

Tue Feb 23, 2021 5:12 am

The black potting material is soft and flexible. It is easily removed with a wooden scraper made out of a bamboo chopstick, sharpen one end like a pencil for fine work and whittle the other end to a flat blade like a screwdriver.

The gray RTV material is more rigid but still flexible. The bulk of it can be carefully sliced and cut with a sharp blade, then use the wooden scraper to get the thin remains off the board. don't try to cut right at the board with the steel blade--don't want to damage the board.

Who1981
Posts: 6
Joined: Sun Feb 07, 2021 12:36 pm
Delivery Date: 05 Feb 2021
Leaf Number: 021208

Re: Onboard charger capacitors failed

Thu Feb 25, 2021 11:35 am

Thanks, good tips. I'll source the parts and start in on it.

I got the eBay charger in. It was a little dirty outside, and smelled slightly hot inside, but other than a couple discolored wires has no signs of failure. I clamped off the coolant lines and swapped in the charger with minimal mess. And it works on 120V and 240V! Charged fully, and drove the Leaf to work today.

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