電動車以其出行便捷、低碳環保的優勢已進入我們的生活，但它的充電器故障率較高很令人頭疼。出于這個緣故，本人根據多年酌維修經驗，總結了電動車充電器的(de)常見故(gu)障的(de)維修方(fang)法，供大家(jia)參考(kao)。由(you)于電(dian)(dian)(dian)動車充電(dian)(dian)(dian)器的(de)輸入電(dian)(dian)(dian)路工作在高(gao)電(dian)(dian)(dian)壓(ya)、太電(dian)(dian)(dian)流(liu)(liu)的(de)狀態下(xia)，因此，故(gu)障率(lv)最(zui)高(gao)。如(ru)高(gao)壓(ya)大電(dian)(dian)(dian)流(liu)(liu)整(zheng)(zheng)流(liu)(liu)三極管(guan)(guan)、濾波電(dian)(dian)(dian)容、開關功(gong)率(lv)管(guan)(guan)等(deng);其(qi)次較易損壞的(de)就(jiu)(jiu)是輸出整(zheng)(zheng)流(liu)(liu)部(bu)分的(de)整(zheng)(zheng)流(liu)(liu)二極管(guan)(guan)、保(bao)護(hu)二極管(guan)(guan)、濾波電(dian)(dian)(dian)容、限流(liu)(liu)電(dian)(dian)(dian)阻等(deng);再就(jiu)(jiu)是脈寬調制控制器的(de)反饋部(bu)分和保(bao)護(hu)電(dian)(dian)(dian)路部(bu)分。

1.保險絲管熔斷

一般情況下，保險絲(si)管熔(rong)斷說(shuo)明充電(dian)器的內部電(dian)路存在(zai)(zai)短路或過(guo)流的故障(zhang)。這是由(you)于充電(dian)器長時間(jian)工作在(zai)(zai)高電(dian)壓、大(da)電(dian)流的狀(zhuang)態(tai)下，內部器件的故障(zhang)率較高所(suo)致(zhi)。另(ling)外，電(dian)網電(dian)壓的波(bo)動，浪涌都會引起充電(dian)器內電(dian)流瞬間(jian)增大(da)而(er)使保險絲(si)熔(rong)斷。

維(wei)修方法(fa)∶首先(xian)仔細(xi)查看(kan)(kan)電(dian)(dian)路(lu)(lu)板(ban)上(shang)面的(de)(de)各(ge)個(ge)元(yuan)件，看(kan)(kan)這些元(yuan)件的(de)(de)外表是(shi)否(fou)被燒糊或(huo)有(you)電(dian)(dian)解液溢出(chu)，聞(wen)―聞(wen)有(you)無(wu)異(yi)昧(mei)。再測(ce)(ce)(ce)量(liang)(liang)電(dian)(dian)源輸入端的(de)(de)電(dian)(dian)阻(zu)值(zhi)，若小于20OkΩ ，則(ze)(ze)說明(ming)后(hou)端有(you)局部短路(lu)(lu)現象，然后(hou)分別(bie)測(ce)(ce)(ce)量(liang)(liang)4只整流二極(ji)管正，反電(dian)(dian)阻(zu)值(zhi)和兩個(ge)限流電(dian)(dian)阻(zu)的(de)(de)阻(zu)值(zhi)，看(kan)(kan)有(you)無(wu)短路(lu)(lu)或(huo)燒壞(huai)的(de)(de);最(zui)后(hou)再測(ce)(ce)(ce)量(liang)(liang)電(dian)(dian)源濾波電(dian)(dian)容(rong)是(shi)否(fou)能進行(xing)正常充放電(dian)(dian)、開關(guan)(guan)功(gong)率管是(shi)否(fou)擊穿損壞(huai)、UC3842及周(zhou)圍元(yuan)件是(shi)否(fou)擊穿，燒壞(huai)等。需要(yao)(yao)說明(ming)的(de)(de)是(shi)，因是(shi)在路(lu)(lu)測(ce)(ce)(ce)量(liang)(liang)，有(you)可(ke)(ke)(ke)能會(hui)使測(ce)(ce)(ce)量(liang)(liang)結(jie)果有(you)誤(wu)或(huo)造成誤(wu)判(pan)，因此必要(yao)(yao)時可(ke)(ke)(ke)把元(yuan)器件焊下來(lai)測(ce)(ce)(ce)量(liang)(liang)。如果仍然沒(mei)有(you)上(shang)述情況(kuang)，則(ze)(ze)測(ce)(ce)(ce)量(liang)(liang)一(yi)下輸入電(dian)(dian)源線(xian)及輸出(chu)電(dian)(dian)源線(xian)是(shi)否(fou)內部短路(lu)(lu)。一(yi)般(ban)情況(kuang)上(shang)，在熔斷器熔斷故障(zhang)中，整流二極(ji)管，電(dian)(dian)源濾波電(dian)(dian)容(rong)、開關(guan)(guan)功(gong)率管、UC3842是(shi)易損件，損壞(huai)的(de)(de)概率可(ke)(ke)(ke)達95%以上(shang)，要(yao)(yao)著重檢查這些元(yuan)器件，就很容(rong)易排除(chu)故障(zhang)。

2.無直流電壓輸出或電壓輸出不穩定

如果保險(xian)絲是完好的，在有(you)負載的惰況下。這類故障要原因有(you)：過壓、過流(liu)(liu)保護(hu)電路(lu)出現(xian)開路(lu)，短路(lu)現(xian)象(xiang);振癆(lao)電路(lu)沒有(you)工(gong)作;電源負載過重，高頻(pin)整流(liu)(liu)濾波電路(lu)中整流(liu)(liu)二(er)極管(guan)被擊(ji)穿：濾波電容漏電等。

維修方法：首先，用萬用表測量高頻脈沖變壓器的各個元器件是否有損壞：排除了高頻整流二極管擊穿、負載短路的情況后，再測量各輸出端的直流電壓，如果這時輸出仍為零，則可以肯定是電源的控制電(dian)(dian)路出了故障(zhang)，最后用(yong)萬用(yong)表(biao)靜態(tai)測量高頻濾(lv)波電(dian)(dian)路中整流二極管(guan)及低壓濾(lv)波電(dian)(dian)容是否損壞，如果上述元器件(jian)有損壞，更換好新元器件(jian)，一(yi)般故障(zhang)即(ji)可排除。但要注(zhu)意：輸出線斷線或開焊(han)、虛(xu)焊(han)也會(hui)造成這種故障(zhang)，在維修時應注(zhu)意這種情況。

3.無直流電壓輸出，但保險絲絲完好

這種(zhong)現象說明(ming)充電器(qi)未工作，或是工作后進入了保護狀態。

維修(xiu)方(fang)法：首(shou)先(xian)應判斷(duan)一下充(chong)電(dian)(dian)(dian)(dian)器的(de)變控芯(xin)片UC3842是(shi)(shi)否(fou)處在(zai)王作狀(zhuang)態或已(yi)(yi)經損(sun)壞。具體判斷(duan)方(fang)法是(shi)(shi)：加(jia)電(dian)(dian)(dian)(dian)測UC3842的(de)7腳(jiao)(jiao)對地電(dian)(dian)(dian)(dian)壓(ya)(ya)，若(ruo)7腳(jiao)(jiao)電(dian)(dian)(dian)(dian)壓(ya)(ya)正(zheng)(zheng)常(chang)并且8腳(jiao)(jiao)有(you)+5∨電(dian)(dian)(dian)(dian)壓(ya)(ya)，1、2、4、6腳(jiao)(jiao)也(ye)會有(you)不同的(de)電(dian)(dian)(dian)(dian)壓(ya)(ya)，則說明(ming)電(dian)(dian)(dian)(dian)路已(yi)(yi)啟振，UC3842基本正(zheng)(zheng)常(chang)。若(ruo)7腳(jiao)(jiao)電(dian)(dian)(dian)(dian)壓(ya)(ya)低，其余管腳(jiao)(jiao)無電(dian)(dian)(dian)(dian)壓(ya)(ya)，則說明(ming)UC3842已(yi)(yi)損(sun)壞。最(zui)常(chang)見的(de)損(sun)壞是(shi)(shi)7腳(jiao)(jiao)對地擊穿(chuan)(chuan)，6、7腳(jiao)(jiao)對地擊穿(chuan)(chuan)和1、7腳(jiao)(jiao)對地擊穿(chuan)(chuan)。如(ru)果這幾只腳(jiao)(jiao)都未擊穿(chuan)(chuan)，而充(chong)電(dian)(dian)(dian)(dian)器還(huan)是(shi)(shi)不能(neng)正(zheng)(zheng)常(chang)啟動，也(ye)說明(ming)UC3842已(yi)(yi)損(sun)壞，應直接(jie)更換。若(ruo)判斷(duan)芯(xin)片沒有(you)壞，則著檢查開(kai)關(guan)這柵極的(de)限(xian)流電(dian)(dian)(dian)(dian)阻是(shi)(shi)否(fou)開(kai)焊、虛焊或變值以及開(kai)關(guan)功率管本身是(shi)(shi)否(fou)性能(neng)不良。除此(ci)之(zhi)處，電(dian)(dian)(dian)(dian)源輸(shu)出線斷(duan)線或接(jie)觸不良也(ye)會造成這種故障，因(yin)此(ci)在(zai)維修(xiu)時(shi)也(ye)應注意(yi)。

4.直流電壓輸出過高

這種(zhong)故障往往是由穩壓(ya)取(qu)樣(yang)和穩壓(ya)控(kong)制(zhi)電(dian)路異常所至，在充電(dian)器(qi)中，直流輸出、取(qu)樣(yang)電(dian)阻、誤差取(qu)樣(yang)放大器(qi)、光耦合(he)(he)器(qi)、電(dian)源控(kong)制(zhi)芯片等共同構成(cheng)了一個閉合(he)(he)的控(kong)制(zhi)環路，任何(he)一處出問題會導(dao)致電(dian)壓(ya)升高。

維修方(fang)法(fa)：由于充(chong)電(dian)(dian)(dian)(dian)(dian)器(qi)(qi)有過(guo)(guo)壓(ya)(ya)保護(hu)(hu)電(dian)(dian)(dian)(dian)(dian)路(lu)，輸(shu)出(chu)(chu)電(dian)(dian)(dian)(dian)(dian)壓(ya)(ya)過(guo)(guo)高首先會使過(guo)(guo)壓(ya)(ya)保護(hu)(hu)電(dian)(dian)(dian)(dian)(dian)路(lu)動(dong)作。因(yin)此(ci)遇到這(zhe)種故(gu)障，我(wo)們可以斷開過(guo)(guo)壓(ya)(ya)保護(hu)(hu)電(dian)(dian)(dian)(dian)(dian)路(lu)，使這(zhe)壓(ya)(ya)保護(hu)(hu)電(dian)(dian)(dian)(dian)(dian)路(lu)不起作用，然(ran)后(hou)測(ce)量開機(ji)瞬間的(de)電(dian)(dian)(dian)(dian)(dian)源(yuan)主電(dian)(dian)(dian)(dian)(dian)壓(ya)(ya)。如(ru)果測(ce)量值比正常值高出(chu)(chu)1V以上，說(shuo)明輸(shu)出(chu)(chu)電(dian)(dian)(dian)(dian)(dian)壓(ya)(ya)過(guo)(guo)高的(de)原(yuan)因(yin)確實在控(kong)制環(huan)路(lu)中(zhong)。此(ci)時(shi)應著(zhu)重檢查取樣電(dian)(dian)(dian)(dian)(dian)阻是(shi)否(fou)變值或損(sun)壞(huai)，精密基(ji)準(zhun)(zhun)電(dian)(dian)(dian)(dian)(dian)壓(ya)(ya)源(yuan)（TL431）或光耦器(qi)(qi)（PC817）是(shi)否(fou)性(xing)能不良、變質或損(sun)壞(huai)。其中(zhong)精密基(ji)準(zhun)(zhun)電(dian)(dian)(dian)(dian)(dian)壓(ya)(ya)源(yuan)（TL431）極(ji)(ji)易損(sun)壞(huai)，我(wo)們可用下述方(fang)法(fa)對精密穩壓(ya)(ya)放(fang)大器(qi)(qi)進行判別：將TL431 的(de)參(can)考端（Ref）與它的(de)陰極(ji)(ji)（Cathode）相連，串1OkΩ的(de)電(dian)(dian)(dian)(dian)(dian)阻，接入5∨電(dian)(dian)(dian)(dian)(dian)壓(ya)(ya)。若(ruo)陽(yang)極(ji)(ji)（Anode）與陰極(ji)(ji)之間為2.5V，并且等侍(shi)片刻還(huan)仍為2.5∨，則(ze)為好管(guan)(guan)，否(fou)則(ze)為壞(huai)管(guan)(guan)。

5.直流電壓輸出過低

根據維修經驗，除穩(wen)壓控制(zhi)電(dian)路會引起輸出電(dian)壓過(guo)低外，還(huan)有以(yi)下幾(ji)點原因：

（1）輸出電(dian)壓端整(zheng)流三(san)極(ji)莒、濾波(bo)電(dian)容(rong)失(shi)效(xiao)，可(ke)以通過代換(huan)法(fa)進行判斷(duan)。

（2）開關功率管(guan)的性(xing)能(neng)下降，導(dao)致開關管(guan)不(bu)能(neng)正常導(dao)通，使電源(yuan)的內(nei)阻增加(jia)，帶負(fu)載(zai)能(neng)力下降。

（3）開關(guan)功(gong)率管的源極通常接一個阻(zu)(zu)值(zhi)很(hen)小但功(gong)率很(hen)大(da)的電(dian)阻(zu)(zu)，作為過流吳護檢測電(dian)阻(zu)(zu)。該(gai)電(dian)阻(zu)(zu)的阻(zu)(zu)值(zhi)―般在0.2～O.8Ω。如該(gai)電(dian)阻(zu)(zu)變(bian)值(zhi)或(huo)開焊、接觸(chu)不(bu)良也會(hui)造成輸出電(dian)壓(ya)過低(di)。

（4）高頻脈沖變壓器不良，不但造成輸出黽壓下降(jiang)，還會造成開關功率(lv)管激(ji)勵不足從而屢損開關管。

（5）高壓(ya)直流濾波(bo)電(dian)(dian)容不良，造(zao)成電(dian)(dian)源(yuan)帶負載能力差(cha)。

（6）電源輸出線接觸(chu)不良(liang)，有―定的(de)接觸(chu)電阻(zu)，造成輸出電壓過低。

（7）電(dian)(dian)(dian)網電(dian)(dian)(dian)壓(ya)(ya)過(guo)低(di)。雖然(ran)充電(dian)(dian)(dian)器在低(di)玉下仍然(ran)可以輸出(chu)額(e)定(ding)的(de)(de)充咆電(dian)(dian)(dian)壓(ya)(ya)，但當電(dian)(dian)(dian)網電(dian)(dian)(dian)壓(ya)(ya)低(di)于充電(dian)(dian)(dian)器的(de)(de)最(zui)低(di)電(dian)(dian)(dian)壓(ya)(ya)限(xian)定(ding)值時，也會使輸出(chu)電(dian)(dian)(dian)壓(ya)(ya)過(guo)低(di)。

維修方法∶首先用萬用表檢查―下高壓直流濾波電容是否變質、容量是否下降、能否正常充放電。如無以上問題，則測量一下開關功率管的電極的限流電阻以及源極的過流保護殮測電阻是否變值、變質或開焊、接觸不良。若無問題，再檢查―下高頻變壓器的鐵芯是否完好(hao)無損。除此z外還(huan)有可能就是輸(shu)出(chu)濾波電容容量降低，或開焊、虛接;電源輸(shu)出(chu)限流電阻變值或虛接;電源輸(shu)出(chu)線虛接等。

這些(xie)困素(su)都(dou)不要放過，都(dou)應仔細檢查，確保(bao)萬(wan)無―失。

6.散熱風扇不轉

這種(zhong)故障原困主(zhu)要(yao)是(shi)(shi)控制風扇的(de)(de)三極管（一般為8550或(huo)8050）損壞(huai)，或(huo)者(zhe)風扇本身(shen)損壞(huai)或(huo)風葉(xie)被(bei)雜物卡住。但有些充電器申采(cai)用的(de)(de)是(shi)(shi)智能散熱，對于采(cai)用這種(zhong)方(fang)式散熱的(de)(de)充電器，熱敏電阻損壞(huai)的(de)(de)概率是(shi)(shi)很大的(de)(de)。

扇(shan)本身損壞，可(ke)以把風(feng)扇(shan)從(cong)電(dian)(dian)(dian)(dian)路板上拔下來(lai)，另(ling)外接上一個12V的直流電(dian)(dian)(dian)(dian)（注(zhu)意(yi)正(zheng)、負(fu)極），看(kan)是否(fou)轉(zhuan)(zhuan)動，還要看(kan)有(you)(you)無異(yi)物(wu)卡住。若擺(bai)動凡(fan)下風(feng)扇(shan)的電(dian)(dian)(dian)(dian)線，風(feng)扇(shan)就轉(zhuan)(zhuan)動，則說明(ming)電(dian)(dian)(dian)(dian)線內(nei)部有(you)(you)斷線或接頭接觸不(bu)良。若仍不(bu)轉(zhuan)(zhuan)動，則風(feng)扇(shan)必壞。對(dui)于采(cai)用(yong)智能散熱(re)的充電(dian)(dian)(dian)(dian)器(qi)來(lai)說，除按(an)上述檢(jian)查外，還應(ying)檢(jian)查一下熱(re)敏(min)電(dian)(dian)(dian)(dian)阻是否(fou)接觸不(bu)良或損壞、開焊等。但要注(zhu)意(yi)此(ci)熱(re)敏(min)電(dian)(dian)(dian)(dian)阻為負(fu)溫度系數，更換時(shi)應(ying)注(zhu)意(yi)。