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by kiev
Sun Jul 22, 2018 5:59 pm
Forum: Batteries and Battery Management
Topic: Troubleshooting and repair for On-board Charger, DC-DC Converter
Replies: 32
Views: 1385

Re: Troubleshooting and repair for On-board Charger, DC-DC Converter

... A few questions: 1. What are the length and diameter in mm of these caps? From your photo I make it to be about 35mm dia. 2. I take it these are part of the output LC filtering and experience full pack voltage? 3. I don't understand their four-terminal configuration. Schematic? Howdy Joe, 1. Lo...
by kiev
Sun Jul 22, 2018 2:19 pm
Forum: Batteries and Battery Management
Topic: Troubleshooting and repair for On-board Charger, DC-DC Converter
Replies: 32
Views: 1385

Swollen Capacitors

2 of the 3 big nichicon 420V 680uF capacitors in jay's box have bowed up the top dome of the relief valve/notch. i don't have a reference designator for them, so for now they are 1,2,3 from left to right, where number 3 is closest to the big hot inductor during charging. https://i.imgur.com/kPrnDma....
by kiev
Sun Jul 22, 2018 1:29 pm
Forum: Modifications & Accessories
Topic: Supplemental cooling for the charger.
Replies: 39
Views: 873

nichicon Charger and DC/DC Converter

The box has a nichicon part number, and looking thru their website i found they take credit for the miev OBC. In fact they claim that it worked so well for Mitsubishi that Nissan converted over to using their design in the Leaf. Here is a page from a product brochure: https://i.imgur.com/YDuVwwf.png...
by kiev
Sun Jul 22, 2018 12:46 pm
Forum: General / Main Owners Forum
Topic: And now my I will not charge!!
Replies: 31
Views: 1146

Re: And now my I will not charge!!

i posted the schematic in the troubleshooting thread. The two big 4.7 Ohm ceramic resistors are connected in series and provide a bypass path across the relay contacts. These are made by Tamura, the larger one with green ink (TAM P10K series) is a thin-film current-limiting fuse, and the smaller one...
by kiev
Sun Jul 22, 2018 6:36 am
Forum: Batteries and Battery Management
Topic: Troubleshooting and repair for On-board Charger, DC-DC Converter
Replies: 32
Views: 1385

PA4080RP100 Board, AC Input Filter and Relay

Jay's charger box has this nichicon part number on the bottom board, so we can use this as a reference designation as needed. Here is the trace for most of the stuff in the bottom board potted region, aka the AC Input doghouse. The two big 4.7R ceramic resistors are connected in series and provide a...
by kiev
Sat Jul 21, 2018 9:53 pm
Forum: Modifications & Accessories
Topic: Supplemental cooling for the charger.
Replies: 39
Views: 873

Re: Supplemental cooling for the charger.

... kiev, did you leave the cover in place and then remove it to make your measurements, or was the cover off the whole time? What's troubling with kiev's measurements is the high temperatures achieved by the magnetics. Even if they used hi-temp insulation, the heat generated and dissipated within ...
by kiev
Sat Jul 21, 2018 7:43 am
Forum: Modifications & Accessories
Topic: Supplemental cooling for the charger.
Replies: 39
Views: 873

Re: Supplemental cooling for the charger.

During the course of dismantling jay's charger i discovered that the 'clear' plastic sleeving and black heat shrink tubing on the inductor and transformer wiring had somewhat melted and fused together. i don't know at what temperature that would occur, but it is likely greater than 360 F. i've never...
by kiev
Fri Jul 20, 2018 2:36 am
Forum: Batteries and Battery Management
Topic: Troubleshooting and repair for On-board Charger, DC-DC Converter
Replies: 32
Views: 1385

Thermal Contact Patch

Seems to be quite small and limited for such a big and heavy box with liquid cooling. Here is the heatsink area in the top plenum covered in thermal paste. i'm going to clean and check the flatness.

Image
by kiev
Thu Jul 19, 2018 6:04 am
Forum: Batteries and Battery Management
Topic: Troubleshooting and repair for On-board Charger, DC-DC Converter
Replies: 32
Views: 1385

Bottom of Bottom Board

i haven't traced the circuits yet, just opened the top of jray's box to remove the boards. This is a view of the plate that attaches to the heat sink. It is covered with a thermal paste that is non-conductive electrically and is really too thickly battered in places--excess compound defeats the purp...
by kiev
Thu Jul 19, 2018 6:01 am
Forum: General Technical Discussions
Topic: Help with scanned error codes
Replies: 20
Views: 712

Re: Help with scanned error codes

The picture shows that the car is in R, Reverse. It will not start and go to READY unless in Park, or Neutral.

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