

| Subject: | Re: No Start Cause: Relay Failure. PICS, Thoughts. |
| From: | David Beierl |
| Date: | Wed, 6 Feb 2013 04:34:39 -0500 |
At 01:42 AM 2/6/2013, neil n wrote: >https://lh4.googleusercontent.com/-h3JODsFUDHM/URHsPfqBbZI/AAAAAAAAGy4/5DkyKweHpnc/s576/Jetta%2520Power%2520Supply%2520Relay%2520Solder%2520Crack.jpg > >https://lh3.googleusercontent.com/-vmq-vUhQT4s/URHsPue73gI/AAAAAAAAGzA/cNsoAUx6cJw/s640/Jetta%2520Power%2520Supply%2520Relay%2520Solder%2520Crack%25202.jpg Fascinating. As Dick says, the flux suggests prior rework. The first image clearly shows a large melt zone caused by arcing around the terminal (delimited by the curved line midway between the terminal and lead), and in the second there appears to be a fracture zone around the righthand lead as well, not surprising under the circumstances. Since 63/37 solder (which solidifies abruptly) is expensive, the solder used in the wave tank will have had a mushy zone between solidus and liquidus. This relay clearly was not designed to be used without a socket to mechanically support the terminals, and/or the mechanical staking of the terminal into the relay baseplate has failed. I'd suggest getting a socket under it or its replacement if at all possible. Yours, d
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