If your Renault Zoe R240 (and old Q210) isn’t charging at a AC station – don’t panic, something probably “exploded.” but we can repair it.
Every month, we receive over 10 vehicles with various symptoms and causes of charging failure. The charging system consists of three key components:
rotor windings (electric motor), EMI filter, and BCB module – and the fault can be in one, or even all of them.
If only the BCB is replaced and the new charging issue reappears, warranty does not cover the typical complaint “it’s not charging again,” because the root cause could be something on other components in the rotor or the EMI filter.
If we followed the approach of authorized services and replaced everything blindly, the repair cost for the Zoe’s onboard charger would reach around €8000 + VAT – just for parts.
Our mission is to make Renault Zoe repairs sustainable, so we approach the issue sequentially: we analyze the entire system and only repair what’s actually defective.
Example:
The EMI filter (MAHLE, new unit: €3400 + VAT) had a melted precharge resistor sealed in epoxy – making it irreparable. New units are overpriced, and used ones are rare and still expensive.
Another common issue is the Infineon IGBT module FS200T12A1T4, which is not commercially available.
If we don’t have it in stock, we’re forced to replace the entire BCB and program it manually.
The design flaw of the entire system lies in poor thermal dissipation: the IGBT is cooled directly to an aluminum casing that must dissipate 22 kW of power (converting AC to DC to charge the high-voltage battery) across a surface of just 13 cm x 7 cm – leading to overheating and failure.
Also, if you’re charging with an empty or faulty A/C system, it’s only a matter of time before we meet.
A dangerous side effect of OBC system failure in the Zoe – one that even charging station operators may not be aware of:
The Zoe can destroy the charger itself, and sometimes even all vehicles plugged in within a 20-meter radius (we’ve witnessed this multiple times).
Prevention?
Other than ensuring the air-conditioning system is properly filled and functioning flawlessly – none.
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OEM component prices:
• BCB: €800 – €1900
• EMI filter: €1800 – €3600
• Electric motor: €4500
EVC repair (total): €1400 – €2800
You can purchase Infineon IGBT stock here: https://evclinic.hr/hr/product/fs200t12a1t4-infineon-hybridpack1-igbt/?v=c4cc1a1ba567
