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Re: Onboard charger capacitors failed

Posted: Fri Feb 19, 2021 7:17 am
by nlspace
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.

Re: Onboard charger capacitors failed

Posted: Mon Feb 22, 2021 12:14 pm
by Who1981
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?

Re: Onboard charger capacitors failed

Posted: Tue Feb 23, 2021 5:12 am
by nlspace
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.

Re: Onboard charger capacitors failed

Posted: Thu Feb 25, 2021 11:35 am
by Who1981
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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