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Electrical - 120VAC Charger Inoperative Diagnostics

Classification: EL11-045

Reference: NTB11-109

Date: December 19, 2011

2011-2012 LEAF; LEVEL 1 EVSE CHARGER INOPERATIVE OR "READY LIGHT" IS NOT ON

APPLIED VEHICLES: 2011-2012 LEAF (ZE0)

IF YOU CONFIRM:

While the Level 1 Electric Vehicle Service Equipment (120vac EVSE trickle charger) is being used and after being plugged into the vehicle and the 120vac outlet, that it does not operate or the green power light does not come on.

NOTE:
Replacement of an inoperative Level 1 EVSE under warranty is only appropriate where failure is due to a defect in materials or workmanship. If the inspection (Action Step 3) shows a blackened varister, the EVSE has been exposed to voltage in excess of the 120vac for which it was designed. The most common cause for this issue is that the customer has plugged the 120vac charger into a 240vac power source with an adapter. This is considered customer misuse, and is not a defect in materials or workmanship that would be covered under the New Electric Vehicle Limited Warranty. Another possible cause is a voltage spike in the 120vac source, for example caused by a lightning strike while charging. This type of vehicle damage caused by environmental conditions is also excluded from coverage under the express terms of the New Electric Vehicle Limited Warranty, although it may be covered under the customer's insurance.

ACTION:

a. Inspect Level 1 EVSE charger for correct operation (see inspection under SERVICE PROCEDURE).

b. If Level 1 EVSE does not pass service procedure inspection, the EVSE has internal damage.

c. If the Level 1 EVSE charging cord assembly has internal damage, perform the inspection of the internal varister and jumper wire of the old unit (see Figure 4). If the EVSE shows a blackened condition on the varister and/or the jumper wire is broken, then it has been subjected to voltages significantly above the 120vac for which it was designed (see Note above).





PARTS INFORMATION

SERVICE PROCEDURE:

WARNING:
Disconnect Level 1 EVSE charger from wall outlet and vehicle before inspection.





1. With Level 1 EVSE charging cord disconnected from the 120vac source, and also disconnected from the vehicle, measure resistance at wall plug end (see Figure 1 above).

^ Resistance of the EVSE cord is measured between the two spaded terminals of the charging cords 120vac wall plug.

^ Resistance should show continuity and measure around 130ohms (depending on the meter).

2. If no continuity is present (open circuit), replace Level 1 EVSE charging cord assembly.

3. If the Level 1 EVSE charging cord assembly is replaced, perform the inspection of the internal varister and jumper wire of the old unit (Refer below). If the EVSE shows a blackened condition on the varister and/or the jumper wire is broken, then it has been subjected to voltages significantly above the 120vac for which it was designed (see Note above).

Checking continuity of Level 1 EVSE (trickle charger) at wall plug.





WARNING:
Confirm that the Level 1 EVSE charger is disconnected from the vehicle and from the 120vac source voltage before opening the charger.

a. Remove screw finishers on back of Level 1 EVSE charger case with 1/8 drill to expose screws.

^ Operate drill at a low RPM until it causes the screw finishers to rotate then lift out gently with drill bit turning.





b. Remove all uncovered 120 torx screws and separate case.











c. Figures 4, 5 and 6 show Level 1 EVSE (cover removed) with damage (circled in red) resulting from the application of voltage greater than the 120vac for which the charger was designed.

^ Looking down on opened charger case with damage circled in red.