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by kiev
Fri Sep 07, 2018 4:14 am
Forum: Batteries and Battery Management
Topic: Any tips to NOT damaging the main battery?
Replies: 18
Views: 358

Re: Any tips to damaging the main battery?

Well i have a dumb idea--just let the car sit unused with a drained pack for a few months. It looks to me that the 12 Cell Monitoring Unit boards inside the pack are constantly powered up using some of the cells in the module to which they are attached. Over a period of time those cells will be pull...
by kiev
Thu Sep 06, 2018 7:12 pm
Forum: Batteries and Battery Management
Topic: Troubleshooting and repair for On-board Charger (OBC), DC-DC Converter
Replies: 226
Views: 8361

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

Hi KIEV: You can add this second Charrger that I am working on as #17 on your Index on this thread. okay thanks, will do. it sounds like you have done a great job of troubleshooting on that unit and may be close to getting it working. Thanks for sharing your notes and the detailed steps that you to...
by kiev
Thu Sep 06, 2018 5:37 am
Forum: Batteries and Battery Management
Topic: Troubleshooting and repair for On-board Charger (OBC), DC-DC Converter
Replies: 226
Views: 8361

General failure thoughts

Some more general theoreticals: So if (during charging) the Aux battery hiccups for some reason, then the DC/DC senses a change in current or voltage such that it goes to the rails trying to maintain the 12V buss--resulting in a huge inrush thru the MCU fuse to the DC/DC. The fuse does it's job of f...
by kiev
Thu Sep 06, 2018 4:46 am
Forum: Batteries and Battery Management
Topic: Troubleshooting and repair for On-board Charger (OBC), DC-DC Converter
Replies: 226
Views: 8361

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

Yes i agree with your excellent summary and like the cascading failure scenarios. In the Elcon charrgers the low voltage power supplies are self-created from the AC input, and in the OBC we rely on the 12V Aux battery to generate them. My loosely connected thoughts were that in either case the loss ...
by kiev
Wed Sep 05, 2018 6:40 pm
Forum: General / Main Owners Forum
Topic: [POLL] On-Board Charger and DC/DC Converter
Replies: 8
Views: 445

Re: [POLL] On-Board Charger and DC/DC Converter

p.s. My theory is that a weak or old 12V battery could let the DC/DC converter, the main contactors, any of the 12V supply relays, or the little boost gate driver power supply inside the OBC, to have a hiccup. Unfortunately any of these will result in a huge and catastrophic electrical spike in the ...
by kiev
Wed Sep 05, 2018 5:18 pm
Forum: General / Main Owners Forum
Topic: [POLL] On-Board Charger and DC/DC Converter
Replies: 8
Views: 445

[POLL] On-Board Charger and DC/DC Converter

Preventative Measures: See 12V Aux Battery Test in this post This poll is open to everyone, please indicate if you have experienced a failure of either the On-Board Charrger or DC/DC Converter or the 20A fuse in the MCU or None (no failure). If possible describe the condition of your 12V Aux battery...
by kiev
Wed Sep 05, 2018 8:28 am
Forum: Batteries and Battery Management
Topic: Troubleshooting and repair for On-board Charger (OBC), DC-DC Converter
Replies: 226
Views: 8361

Boost Gate Driver Sketch and Notes

It looks like the gate drive command comes from the top board on CN1 pins 30 and 32 up to Q506 and 507 on the primary side of T502 and 501. These are 2SC5053 NPN, while the transistors on the secondary side Q502, 503 and Q501, 504 (underside of board above the waffle plate) are 2SA1900 PNP. The diod...
by kiev
Tue Sep 04, 2018 2:31 am
Forum: Batteries and Battery Management
Topic: Troubleshooting and repair for On-board Charger (OBC), DC-DC Converter
Replies: 226
Views: 8361

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

The opamp went to the rail and the controller shut off the FETs immediately was my guess on how the loose resistor could cause the spike, back in Schema 7 With the twisted sister resistor going open circuit, then the op amp becomes a non-inverting follower with a gain of 1+(39/20) = 2.95, and now th...
by kiev
Mon Sep 03, 2018 8:31 pm
Forum: Batteries and Battery Management
Topic: Troubleshooting and repair for On-board Charger (OBC), DC-DC Converter
Replies: 226
Views: 8361

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

i'm working on jray3's charger which had the same symptoms--blown fuse in the MCU and blown snubber caps. i'm thinking it is caused by a huge inductive spike when the boost stage switching gets interrupted. There are the two transformers plus the two inductors in the upper right corner. Check all th...
by kiev
Sun Sep 02, 2018 5:45 pm
Forum: Instruments - Radio/USB/Nav - CAN - Climate Controls - Remote
Topic: EV-ECU Reverse Engineering
Replies: 0
Views: 127

EV-ECU Reverse Engineering

This may be overly optimistic and entirely premature, but here are pictures of the top and bottom of the board to get it started. Con1 is the main box connector which is subdivided into 4 separate connectors marked A-D on the board. Con2 and 3 look like unpopulated programming ports, such as JTAG fo...

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