Driver pack problems

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Datatek

Well-Known Member
Posts
43,864
Location
Near Poitiers SW France
Let me start by saying that what follows WILL NOT be the answer to all driver pack problems and this post may even be a bit premature.

At the start of this year, My P38 started throwing up the occasional fault:- "Air pressure signal constantly high".
This fault has often been associated with driver pack problems so I swapped the driver pack, after 6 months the problem had not recurred confirming that the driver pack was the likely cause. I'm guessing, but I believe the "Air pressure signal constantly high" is a bit like " Vehicle has moved" in that it's logged when the ECU cannot identify the fault.

So, on to looking at the defective driver pack. It was immediately obvious that there was an area of overheating that had blackened and cracked the potting compound. Unfortunately I didn't take a photo but I knew it was in the position of a 100uf 63V electrolytic.

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I dug out the potting compound with care and it was obvious that the electrolytic had been getting very hot at some point. I cut the wires and soldered in a new electrolytic to the short ends of wire left above the PCB and re-sealed it.

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Now, I said that this post may be a bit premature, that is because the repair has only been on test for a month or so which may not be long enough. I will update if the failure recurs.

The electrolytic is across the power lines to the driver pack, it's function can be looked at in two ways, as a storage device providing a reservoir of power for solenoid activation, or it could be said it stops voltage fluctuations reaching the EAS ECU and upsetting it, electrical noise in other words.
 

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I'm still part way through digging compound out of my dodgy driver pack. Bench testing has proved there's definitely dodgy connection on some of the wires going into the rubber, but not got the PCB removed yet. Highly likely I also have dry joints on other components, but time will tell.

If somebody can figure a way to easily remove the compound, then fixing driver packs will be easy.

Pete
 
Anyone tried acetone to remove potting epoxy?

Also heat

get the board up to 100C and the compound should go chalky and be easier to pick off
 
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I'm still part way through digging compound out of my dodgy driver pack. Bench testing has proved there's definitely dodgy connection on some of the wires going into the rubber, but not got the PCB removed yet. Highly likely I also have dry joints on other components, but time will tell.

If somebody can figure a way to easily remove the compound, then fixing driver packs will be easy.

Pete

I picked the compound out.
Not found any dry joints so far, but no doubt some boards will suffer.

Anyone tried acetone to remove potting epoxy?

Also heat

get the board up to 100C and the compound should go chalky and be easier to pick off
Acetone does not work and 100C will damage components.
 
After digging out some of the compound, I tried soaking a few pieces in various solvents. Only thing that did help was Silicon Remover from Screwfix, but even that only gets the surface of the rubber slightly crumbly.

P.
 

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After digging out some of the compound, I tried soaking a few pieces in various solvents. Only thing that did help was Silicon Remover from Screwfix, but even that only gets the surface of the rubber slightly crumbly.

P.

Have you tried a Stihl saw? :D:D:D
 
Hey Datatek, so i swapped my Driver pack out as part of my EAS re-build project...
haven't had any of my previous errors, faults and Jumping to wade / dumping air as yet... but only don't about 60 miles.. so don't want to get too excited...
did i read a post someplace by you interested in looking at packs from people that had been mis behaving ?
 
Hey Datatek, so i swapped my Driver pack out as part of my EAS re-build project...
haven't had any of my previous errors, faults and Jumping to wade / dumping air as yet... but only don't about 60 miles.. so don't want to get too excited...
did i read a post someplace by you interested in looking at packs from people that had been mis behaving ?
No you didn't but if you want to send it to me I would not say no.
No idea if I could fix it or when I would have time in the near future as I'm in the middle of fitting a new kitchen.
 
Happy to post it to you if your interested! Pm me yr address. No rush,but if you get time to look and play with it all good. Even better if you find a fault and think you can fix it
Kitchen allowing ......
 
Happy to post it to you if your interested! Pm me yr address. No rush,but if you get time to look and play with it all good. Even better if you find a fault and think you can fix it
Kitchen allowing ......

You may reconsider that when you find out how much the postage to Froglandia is. :D:D:D
 
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