Polar Home Charger Fault

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This topic contains 28 replies, has 7 voices, and was last updated by  Trevor Larkum 3 months, 3 weeks ago.

Viewing 9 posts - 21 through 29 (of 29 total)
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  • #32054

    andyfras
    Participant

    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.

    #32055

    andyfras
    Participant

    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.

    #32059

    Trevor Larkum
    Keymaster

    @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?

    #32061

    andyfras
    Participant

    It’ll be less than that.

    I’ve sent you an email.

    #32103

    Trevor Larkum
    Keymaster

    Thanks – I’ll send it as soon as I can.

    #32555

    andyfras
    Participant

    Trevor, please check your spam folder, as I’ve sent several emails with no reply from you.

    #32672

    andyfras
    Participant

    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.

    #32694

    Trevor Larkum
    Keymaster

    Sorry Andy – just back from a holiday in Venice (The Predicament of Venice). I’ll respond directly to your latest email.

    #32713

    Trevor Larkum
    Keymaster

    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.

Viewing 9 posts - 21 through 29 (of 29 total)

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