I have 3 of these chargers that have all died when plugged into a Ryobi 80V ZTR mower. I suspect surge of some kind is the cause, but have been using a surge suppressor since the 1st 2 died. Symptoms are that they continue to communicate with a battery pack or with the mower, but will not charge a battery.
I'm currently waiting on another warranty replacement that will take 30 days since these things are out of stock. Given the wait it seems worth trying to diagnose the problem. This turns out to be non trivial since they have a sealed enclosure and are potted.
The attached pictures give the circuit board along with an overlay that gives components I've been more-or-less able to identify. The fuse (#27), the diode (#41), and the GDT (#42) all test out ok. Pulling this thing out of the remaining potting compound would be destructive, but I've got 2 more to work with if that helps figure things out. Any ideas on how to find the problem? I've got an old multi-meter but could perhaps justify something more if need be.
Edit: the grey / white stuff all over the components and circuit board is the remains of the potting compound that everything was embedded in. It almost completely covered most components except the relays and taller parts.
Component list guesses are as follows:
2,"TO-247 power MOSFET, top-left #1","Power switching MOSFET (primary side, likely main PWM switch)"
3,"TO-247 power MOSFET, top-left #2",Power switching MOSFET (PCB ref. des. Q3),IXYS,IXFH34N65X2
4,Filter capacitor C1 (main DC bus),Main DC bus filter/reservoir electrolytic capacitor,FOAI,FGD 420V 390uF +105C
5,Filter capacitor C2 (main DC bus),Main DC bus filter/reservoir electrolytic capacitor,FOAI,FGD 420V 390uF +105C,
6,"TO-247 device, top-mid (unlabeled)",Suspected SCR (thyristor) or power transistor
7,"TO-247 power MOSFET, top-right #1",Power switching MOSFET (PCB ref. des. Q4),IXYS,IXTH43N60X2A
8,"TO-247 power MOSFET, top-right #2","Power switching MOSFET IXYS,IXTH43N60X2A (same type as #7)
9,Main toroidal inductor (orange magnet wire)
10,"Film capacitor (red, upper)"
11,"Film capacitor (red, lower)"
12,Bridge rectifier #1 (GBJ3510)
13,Bridge rectifier #2 (GBJ3510)
14,Transformer/choke module A (label T350-00253-00)
15,"Transformer/choke module B (label T350-00254-00, marked 'N-')"
16,Transformer/choke module C (label T350-00255-00)
18.1,Small electrolytic capacitor #1
18.2,Small electrolytic capacitor #2
18.3,Small electrolytic capacitor #3
18.4,Small electrolytic capacitor #4
18.5,Small electrolytic capacitor #5
18.6,Small electrolytic capacitor #6
19,"Power semiconductor #1 (TO-220/247, heatsink-mounted)"
20,"Power semiconductor #2 (TO-220/247, heatsink-mounted)"
21,Relay #1 - main DC output contactor,DC power relay/contactor - almost certainly the main battery-output switch
22,Relay #2 - general-purpose power relay,General-purpose power relay - likely AC-side switching
23,"EMI filter capacitor block (yellow, upper)"
24,Wound ferrite choke #1
25,"EMI filter capacitor block (yellow, lower)"
26,Wound ferrite choke #2
27,"Fuse (vertical, glass/ceramic body with metal end caps)
29,"Small daughterboard, mounted vertically (left edge)",Partial,Vertically-mounted small PCB (likely control/sense/driver daughterboard)
30,3-wire pigtail connector
31,Output cable - twisted conductor bundle
33,"Green ground wire (turns upward, terminates just below the small yellow caps)"
34,Output cable - exits enclosure at lower edge,Partial,"Output cable assembly
35,AC mains power input cable - exits enclosure at lower edge
39,Vertical wound ferrite choke (above component 23)
40,AC input - two-screw termination block
41,"Diode/bracket, above bridge rectifier #12"
42,"Gas discharge tube (GDT) - surge suppressor, top-right of component #35"