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Black and Decker 20V DC Lithium Sweeper Circuit Board Repair - Help.

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cajoromi

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Hi,

my leaf blower stopped working and upon taking it apart I discovered burn marks on the circuit board. The marks were around what appears to be two solder dots as outlined in the photo's I've attached.

Can anybody please help to identify this specific part and tell me, if possible, how to repair it? My electrical knowledge is limited but I'll do my best to assist with any inquiries.

Sorry in advance for the quality of the pictures.

Any instructions or suggestions would be greatly appreciated.
IMG_20190726_113815 burnt.jpg
IMG_20190726_113956 burnt.jpg
 
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That looks like there was a resistor there; look around inside the casing for a part about that size.

Looking at how it's wired, that a PWM driver section for the motor; the driver is the 8 pin chip, and the lower part would be a diode, near the red wire there.

That would likely be a current limit resistor/fuse, and it looks like it did its job, lol.

I would guess it would be a small value resistor, like 0.1 ohms or smaller.

I'd try a single strand of wire from a piece of multistranded appliance cord; one "thread" out of an 18awg zip cord cable is about 40awg, and that blows at about 20A.

If you can find the original part, there may be a number on it, but I doubt it.

Make sure the motor spins easily before you do this; the motor stalling is what cause this, either there was crap in there, or the bearings in the motor are bad.

Try it before you put it together, it's easier to put out if it catches on fire. :)
 
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What part? You said yourself it was two solder points. What is on the other side of the board at those points? If this is the first time you opened it, it is highly unlikely there used to be a component there that has suddenly disappeared and/or vaporized.

That said, just because you see what appears to be burn marks, that does not mean the faulty component(s) is (are) anywhere near those points. The "short" (assuming a short) could be anywhere in that same circuit, but the excess current affected that area first. Even so, it is more likely another component has now "opened", though there may be no visible signs of that.

Even if the offending component could be isolated unless labeled, the specifications for the device likely cannot be determined. So, for example, if a capacitor, what value. If that IC, what is the replacement part number?

If me, if the motor spins freely with my fingers, I might stick a large 12V battery (perhaps from an UPS?) on that motor to see if it spins. If it does, then I would probably research that entire circuit board and go for replacing it.

Speaking of batteries, are you sure the one for that is charging?
 
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LOL. Board swappers kill me.

To the OP:

This is similar to the circuit you're looking at,at least at the driver side of it:




The 8-pin chip you see is Q1, the black component I identified is D2, and the missing part is the current limit, R10. Your motor is where this one says "hydrogen cell."

This is called a "Single Ended PWM Driver".

The rest of the control circuitry this shows is in the big chip at the center of your pic. It may be a TL494 or a newer variant; those are in everything.
It also uses the other transistors there; yours is also a Li-ion charger, so some of the circuitry on your board does that.


The PCB itself is no longer available, and there's no drawings available; The whole blower is available for $40 online, so taking it somewhere to get it fixed is going to be too expensive.


I'd solder a small piece of wire across the terminals where the resistor was; the resistor is going to be a very low value.
The one in the drawing above is 0.003 ohms, that's a larger piece of wire than I'm talking about using above.
Start small, if it unsolders itself at mid or full speed only, then use two pieces of wire, and keep going up until it quits doing that and glowing red. :)

If the transistor chip is bad, The added wire will glow red hot and unsolder itself instantly, like the original part did; the blackened part is where the thin, last piece of solder vaporized due to the current going thru it as is came off the board.

I've designed and repaired this kind of stuff for over 30 years; it's not hard to fix, if you can recognize the circuitry.


If you want, read and post the numbers off the transistor, diode, and control chip, and I'll see what I can find out for you.

A well focused pic, where I can read them is even better. :)

Search for the missing part; It's there somewhere.
These kinds of things start to fail, then we smack them, and the molten solder allows the part to fall off.

Modern SMT parts are on an alumina substrate, and resistors this small in value are metal films, so they get really hot, and melt the solder.
If you find it in one piece, you might be able to solder it back on.
:)

You are likely to find the bearings are tight, if so, clean and lube them; check for hair wrapped around the shaft, or anything else that binds up the motor.
The harder the motor has to work, the hotter the circuit runs.
The only cooling is where the copper areas of that board are plated with copper; see all the holes? Those are called "Thermal Vias" and tie the fron of the board to the big copper area on the back of the board.
2" square will dissipate ~2 watts of power, in a limited area like that, if the air blows across it too.

The part that failed is the part designed to fail; it's a nice design.
Dewalt makes B&D; a buddy worked there doing failure prediction analysis. :)

Do you have a voltmeter, and know how to check a diode?
Take the battery out, and check the main parts.
Measure across the 8 pin chip, from the ganged leads on one side, to the 3 ganged leads on the other side; one way should be open, the other way should measure like a diode. (0.6v)
Measure the diode, same thing, one way open, other way ~0.6V.
If either are shorted both ways, there's the main problem. :)
The numbers will tell you what to buy; Digikey or Mouser will have parts that will work.

Good luck with it. :)
 
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cajoromi

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Thank you both for your reply but a thousand thanks to you, Grog6, I did as you said and it's running like new. Problem solved!
 
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I like to fix stuff.

Watch for smoke, or weirdness; Li stuff has a propensity to catch on fire if it draws too much power.

I'm happy to help!
 
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IMO, replacing an unknown resistor based on a different circuit board is risky. Recommending someone else do it on their board is simply bad advice!

For one, we don't even know if it was a resistor or the value of it. What if it was a fusible link that blew due to too much current? Now, with a complete short in there, there will be even more current causing the potential for a lot more than smoke. :(

@cajoromi - this is not a good move. I'm glad it works but I strongly advise you to store this sweeper outside, as far away from the house as possible, and away from other flammables, like fuel for a lawn mower. If not possible to store away from the house, at least remove the battery EVERY TIME it is not in use!
 
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By that logic, you should never repair anything.

The resistor in question isn't in the charging circuit, and is only functioning when the switch is on; if it works once, it will work all successive times the same way.

It's not any more dangerous than it was; the hardest part is sizing the resistor to be similar in value.

I recognize the circuit, I know how it works, and this is a valid fix.

A piece of small wire is very similar to a 0.003 ohm resistor. :)

Electronics isn't some mysterious Magic, it works in very defined ways.

I bet you learned electronics in the military, right? :)
 

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Thank you both for your reply but a thousand thanks to you, Grog6, I did as you said and it's running like new. Problem solved!

Glad you got the Leaf blower fixed.
Problem solved, thread closed.
 
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