May 15, 2017 at 08:32 #32054
Yes it is, you’ll also find that C44 is only rated at 6.3V, when it should be at least 16V. I can see that both C63 and C44 are ‘doming’ as a result of this.May 15, 2017 at 08:54 #32055
There was no degradation of the other capacitors on the one charger that I repaired, so it may be enough to just replace these 2 wrongly rated/fitted capacitors.May 15, 2017 at 20:22 #32059
@andyfras – I’d be very happy to take you up on your offer of a repair. I’ve no idea what would be a reasonable charge – perhaps £50?May 15, 2017 at 22:29 #32061
It’ll be less than that.
I’ve sent you an email.May 17, 2017 at 20:14 #32103
Thanks – I’ll send it as soon as I can.May 28, 2017 at 11:34 #32555
Trevor, please check your spam folder, as I’ve sent several emails with no reply from you.May 30, 2017 at 11:38 #32672
Still no reply from Trevor, but here’s the progress report:
The charger is fixed.
After changing the capacitors, the charger board still booted to a red light. There is evidence that the board had been running very hot. After more investigation, I discovered that the output contactors are shorted, which means that they are constantly live. It looks like excessive current has been drawn at some point. I also found that the energising relay for the contactors has variable contact resistance, so I’m wondering if this has meant that the contactors were not pulling in properly, and maybe chattering. This could cause the contacts to overheat and eventually weld themselves shut. Both contactors make a loud buzzing noise when energised; I tested a good one, and there’s just a quiet hum.
I removed the contactors to confirm where the short is, and they are both definitely short circuit (the board is OK). For some strange reason, the 2 contactors are connected in series, both driven by the same relay, so that they switch together. I can see no reason for this, so I replaced just one of the contactors, and wired the other across. I also replaced the energising relay.
I have tested it by charging may car for about 30 mins and all is well.May 30, 2017 at 22:12 #32694
Sorry Andy – just back from a holiday in Venice (The Predicament of Venice). I’ll respond directly to your latest email.June 2, 2017 at 09:06 #32713
Thanks for sorting it Andy. I reinstalled it last night and the car charged fine immediately. I’ll try a timed charge tonight, but I expect that will work too.October 2, 2017 at 23:02 #41980
My ChargeMaster gave my red light this summer, I have exchanged all the electrolyte capacitors and SMD but still getting the red error led.
When starting the unit it flashes the green/yellow for a while then everything goes out and the ready led is on, plug it to the car and I get an error.
I found an R182 resistor got bad but replacing it didn’t make any difference any suggestion.
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