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

Wed Mar 18, 2020 7:21 pm

i know it's long, but how much of this thread have you been able to read? The first 2 posts have an index and links to other failures, there is also some schematics links.

On page 45 is a schematic with the diode voltages that you can use to check if the high power semiconductors are shorted or open. These are measured at the solder joints on the bottom board. Dionisis posted a really nice cleaned up version up a few posts on the previous page.

i don't know how to check a unit without in a car, we just don't know how to command (CAN buss) to make it work on a test bench. i usually start at the beginning, where the AC comes in and just measure and check every component in the path, check the diode drops, and check the output circuit. Look for burnt or damaged parts. e.g. look at the little diode D301 across the AC relay coil circuit--if it is shorted then the relay won't be able to work.
kiev = kenny's innovative electric vehicle

Virusman
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Joined: Wed Jan 29, 2020 1:21 pm

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

Fri Mar 20, 2020 3:53 pm

i know it's long, but how much of this thread have you been able to read?

belive me... maybe not all but a lot of from this thread.
neverminde

I found something, this one diode is shorted. Is it DF20L60U?
My plan is to desolder waffle plate, cut leads and solder in that place new diode, I think I should put diode as close as possible bottom plate (heat sink) what is your opinion about that?

Image

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

Fri Mar 20, 2020 6:23 pm

i had a really hard time trying to cut thru the black epoxy, but if you could remove it then it should be possible to replace the diode(s).

Did you happen to see the picture on page 6
viewtopic.php?f=23&t=4079&start=50#p36810

it shows the layout of the diodes. That schematic you are using was made before i had access to see the actual arrangement--there are 10 diodes in the upper right quadrant of the waffle plate.
kiev = kenny's innovative electric vehicle

Virusman
Posts: 9
Joined: Wed Jan 29, 2020 1:21 pm

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

Mon Mar 23, 2020 3:58 pm

Hi, I checked once again the diodes with this new schematic (10 diodes). I disconect all connection I check once again and figured out thtat diodes are ok but connection betweend diodes and trafo's is not. I have to wait for my phone, I got there some pictures from previous repair and I will able to check thtat connection with photos. Before me France guys try to repair it, maybe they make a mistake with connection.

Virusman
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Joined: Wed Jan 29, 2020 1:21 pm

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

Thu Mar 26, 2020 2:12 pm

Hi again guys, could some one check connection on board for two trafos?
See photo beloow:
Image

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

Thu Mar 26, 2020 7:08 pm

Looking at your picture--do you have the BLUE and GREEN on the wrong Tabs? They appear to be reversed, but it is hard to see from that picture.

i think you have the secondary sides of the transformers correct. T5 and T6 are the secondary outputs of transformer 1; and T7 and T8 are outputs for trans 2.

The primary side is the T1A and T1B, which should have BLUE wires coming off the Faston tabs of the board and right next to the Y1 tab (yellow wire to T5).

The other primary wire is the T4A and T4B, which have GREEN wires in the Faston tab covers.

When i put them back together, i start at the bottom of the tabs with the GREENs, then the BLUEs, then Yellow1 and Black1, followed by Black 2 and Yellow 2.

The Output filter coils N and P, are the Gray and Red wires; those appear okay.

Image
kiev = kenny's innovative electric vehicle

Virusman
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Joined: Wed Jan 29, 2020 1:21 pm

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

Fri Mar 27, 2020 2:53 pm

THX. Looks ok, green and blue are in the same order as on your schematic.

bigpete
Posts: 8
Joined: Mon Mar 30, 2020 1:04 pm

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

Tue Mar 31, 2020 1:42 am

ChristopheFR wrote:Hello Kiev,
I changed all this components :
Image

Both 4.7ohm resistor were fused
2.2µF capacitor was inflated
One of three 680µF capacitors was inflated, (I changed three)

To prevent other failures, I changed both 1000pF capacitors, and the relay

I just tested the 12VDC on the 12th pin
With the charrger cable not connected, I get 0VDC
With the charrger cable connected, I get 12VDC for 2 or 3 seconds, and it stops

If I connect my Icarsoft I970, I get this message :
What do you think?
Image


Hi, I have also a problem like yours and plan to replace the same parts in a attempt to fix it. Do you have a copy of your parts order? Need to know which parts and where I can buy them? I live in Norway and here we got 220V, what do you have (in order to get the correct parts)?

bigpete
Posts: 8
Joined: Mon Mar 30, 2020 1:04 pm

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

Fri Apr 03, 2020 1:01 am

DBMandrake wrote:
kiev wrote:Those are great looking snubber caps and a super find to get 6kV rating. Awesome solder job too.

Thanks. :)

These are the caps I ordered, however I notice that the picture shown is NOT accurate as the ones I received were orange, not yellow, and a lot thicker:

https://uk.rs-online.com/web/p/ceramic- ... s/8313240/

I suspect the picture is from a lower rated capacitor in the same series.
This isn't very pretty but has the measured diode drop voltages on a good waffle plate, with no caps or inductors connected with the fastons.

When you say with no capacitors connected do you mean the electrolytics were removed ?


Thanks for the post, very helpful. I have ordered the capacitors from RS but they are out of stock so I have to wait until april 30. Does anyone knows other places to order these capacitors from?

misterbleepy
Posts: 222
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Location: Newquay, Cornwall, UK

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

Fri Apr 03, 2020 5:11 am

bigpete wrote:Thanks for the post, very helpful. I have ordered the capacitors from RS but they are out of stock so I have to wait until april 30. Does anyone knows other places to order these capacitors from?


This looks like a similar one to that:

https://uk.farnell.com/vishay/s102m59z5 ... 1nF%206kV#
Keith B.
driving with the power of 15.667 kettles

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