http://zeromanual.com/history/Gen2/Calex_Charger/Damage_Report?feed=atom&Gen2/Calex Charger/Damage Report - Revision history2024-03-28T09:13:20ZRevision history for this page on the wikiMediaWiki 1.27.0http://zeromanual.com/index.php?title=Gen2/Calex_Charger/Damage_Report&diff=5555&oldid=prevBrianTRice: BrianTRice moved page Calex Charger Teardown to Gen2/Calex Charger/Damage Report2020-01-12T21:19:15Z<p>BrianTRice moved page <a href="/wiki/Calex_Charger_Teardown" class="mw-redirect" title="Calex Charger Teardown">Calex Charger Teardown</a> to <a href="/wiki/Gen2/Calex_Charger/Damage_Report" title="Gen2/Calex Charger/Damage Report">Gen2/Calex Charger/Damage Report</a></p>
<p><b>New page</b></p><div>This showcases a teardown and de-potting of a Calex 1200 charger from a 2016 DSR model, following a total failure of the charger.<br />
<br />
[[File:2016-dsr-calex-1200-depotting-3.jpg|400px|thumb|none|Board topside completely uncovered]]<br />
[[File:2016-dsr-calex-1200-depotting-7.jpg|400px|thumb|none|Board underside mostly uncovered]]<br />
<br />
;Notes<br />
: Odometer estimate when the charger failed: 31000 miles.<br />
: Symptoms observed prior to the fault:<br />
:* Excessive sparking at the inlet despite cleaning and using a hospital-grade cord.<br />
:* Prior failure at 30,000 miles of the Sevcon DC-DC converter.<br />
<br />
;General Observations<br />
* A component on the board overheated and caught fire.<br />
* The fire burned through the board.<br />
* The rubbery potting extinguished and contained the fire.<br />
<br />
;Design Observations<br />
* The board is mounted on the upper side of the charger casing, with the largest/heaviest components suspended below it within a great mass of potting.<br />
*: The board itself is mounted very close to the surface that is flush with the underside of the main powerpack casing on the S platform.<br />
* The rubbery potting fills the case volumetrically, and is likely poured in as a substance which then sets chemically or thermally.<br />
* The board surface is nearly as large as the enclosure, and seems too thin for its span to support the mounted components on its own.<br />
*: The components seem mainly supported by the potting.<br />
*: The board's unusual size could be an attempt to increase the distance between components.<br />
*: This might be intended to reduce the intensity of heat buildup inside the charger, after the 2014-2015 design proved to be prone to failure.<br />
* The board's capacitor banks do not seem adequately shielded from current inrush.<br />
*: This lack of shielding probably plays interacts with a dirty charging inlet and possibly also interacts with a glitchy DC-DC converter on the main/output bus.<br />
<br />
;References<br />
* [https://zeromotorcyclenotes.blogspot.com/2019/02/stock-charger-teardown.html Stock Charger Teardown blog post] shows a 2015 S' charger with a somewhat different board layout.<br />
<br />
The photos presented are all oriented with the rear/connection side of the charger pointing to the right.<br />
<br />
<gallery mode="packed" caption="Uncovering the topside of the board"><br />
File:2016-dsr-calex-1200-lid.jpg|Calex 1200 top lid<br />
File:2016-dsr-calex-1200-potting.jpg|Top potting revealed<br />
File:2016-dsr-calex-1200-depotting-10.jpg|Under the covering plate<br />
File:2016-dsr-calex-1200-depotting-8.jpg|Covering plate, once removed<br />
File:2016-dsr-calex-1200-depotting-9.jpg|Carving (1)<br />
File:2016-dsr-calex-1200-depotting-2.jpg|Carving (2)<br />
File:2016-dsr-calex-1200-depotting-6.jpg|Carving (3)<br />
File:2016-dsr-calex-1200-depotting-1.jpg|Carving (4)<br />
File:2016-dsr-calex-1200-depotting-3.jpg|Board topside completely uncovered<br />
</gallery><br />
<br />
<gallery mode="packed" caption="Uncovering the underside of the board"><br />
File:2016-dsr-calex-1200-depotting-4.jpg|Massive covering heatsinks revealed<br />
File:2016-dsr-calex-1200-depotting-5.jpg|Largest heatsink plate removed<br />
File:2016-dsr-calex-1200-depotting-7.jpg|Board underside mostly uncovered<br />
</gallery></div>BrianTRice