Common faults and maintenance of chargers
1. The output voltage is normal, but the charging current is very small
When encountering this situation, the voltage components should be checked for poor contact or damage. If everything is normal, the charger should be replaced to troubleshoot.
2. Severe heating, even with shell burning and deformation phenomenon
This is mainly due to some users frequently carrying it with the vehicle, causing some components to become loose and causing malfunctions. The main manifestations are: abnormal voltage working state, high heat, severe deformation of the charger shell, burnt circuit board, resulting in voltage damage. The solder joints can be re soldered. If the fault cannot be eliminated, it is necessary to check if there is an open circuit in any components.
3. When charging, the power indicator light is on, and the charging indicator light is orange
Firstly, please check if the output plug of the charger is tightly connected to the charging plug of the battery box. If there is no problem, you can check if the fuse on the battery box is open or if the fuse holder is loose and has poor contact.
In addition, some car models require the battery lock to be opened before charging. If all the above faults are resolved, consider whether the output line of the charger is open. You can use a multimeter voltage range (200V range) to measure the no-load output voltage of the charger, which should be 41-44V (with 36V batteries depending on the charger). If not, it may be due to an open circuit in the output line of the charger. Turn on the charger and replace the output line to troubleshoot.
Attention: When replacing the output line of the charger, be sure not to reverse the positive and negative connections of the original machine.
4. The power indicator light is not on, the charging indicator light is not on, and the charging indicator light is also not on
Check if the input power plug of the charger is properly connected. You can plug the charger input plug into a normal power socket. If the situation still persists, open the charging case and observe whether the fuse connection inside the machine is intact and whether there is an open circuit. If there is no open circuit, check if the power input line is still in good condition. After troubleshooting the power input line, check if there is any virtual soldering phenomenon in the components near the high-voltage area on the circuit board. In addition, an open circuit can also lead to the above-mentioned faults. If the fuse inside the machine has been broken, do not replace the fuse in the ampere (the fuse tube of the charger is generally 2A), and focus on checking whether its components are damaged. If there is damage, it can be replaced with the same type.
5. Heat generation, accompanied by abnormal noise, unable to charge
The cause of the malfunction is due to damage to the output stage's damping capacity. In addition, open circuits or virtual soldering of components can also cause the above-mentioned faults.
6. The copper foil in the output section is burnt out
After turning on the charger, the copper foil on the output part of the charger is burnt out, which is usually the result of the reverse connection of the positive and negative poles of the battery. The resulting fault will cause damage to many components of the charger. If the charger fuse is not damaged, it is usually restored to normal by connecting the broken copper foil after replacing the components. If the fuse of the charger is broken, the fault is more serious and it is possible to inspect and replace each damaged component one by one.
7. There is abnormal noise during operation, and the power indicator light and charging indicator light are dim and flashing
The cause of the malfunction is damage to the components. The damaged components can be replaced and the output voltage of the charger should be within the normal working range.
8. The output voltage is very high
The output voltage is very high (at 50V), and the cause of the fault is a short circuit or open circuit in a certain component. With this judgment, the pin voltage of the integrated circuit can be measured.
Note: After replacement, the output voltage of the charger in the car should be measured again with a multimeter. The normal value should be between 41-44V. If there is any deviation, the components should be adjusted to maintain the normal output voltage of the charger.
