Bjron
Posts: 19
Joined: Tue Nov 13, 2018 11:05 pm

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

Fri Nov 23, 2018 2:16 pm

3 days ago citroen maintenance did what was in bulletin. And no ready mode.

They maded ticket to Citroen headquarter and today they got reply..

8000eur/$ inverter need change. No condensator bank available as sparepart..

Happy Thanksgiving ;)

Ill change 80kw inverter to car.

ChristopheFR
Posts: 19
Joined: Sat Aug 11, 2018 1:08 am

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

Sun Nov 25, 2018 2:03 pm

Hello tout le monde,

So I repaired my charrger

All details are on the following thread:
http://vehiculeselectriques.fr/viewtopi ... 60&t=16287

Unfortunatly , It does not work : I can not get into the ODB to clear it and reset,

With an Icarsoft i970: no communication on the On board charrger section
With an MX808 Autel, no communication either
And finally at Citroën, no communication either with Lexia (Citroën system)


What I think: the top PCB is not powered, due to another problem on the bottom PCB

Ideas to continue the repair ?

kiev
Posts: 858
Joined: Sun May 03, 2015 7:15 am
Location: The Heart o' Dixie
Contact: Website

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

Mon Nov 26, 2018 8:35 pm

Sorry to hear that it's not working. When you say that you repaired the chargger, did you find any specific failed components?

What clues make you think that the top board is not getting power? i don't know a good test point location offhand, but you would want to very carefully check that 12V is coming into the board thru CN101. Don't slip and accidentally touch something to the 12V trace--that would cause major damage. Maybe check on the backside of the connector to prevent accidental contact.

There will be 3 possible outcomes: either 12V present, no voltage present, or some other voltage present (e.g. 12V being pulled down by short on the board).

The top board creates several different voltages from the 12V power it receives thru the CN101 connector. It sends commands to the bottom board, and receives sensor feedback signals used to regulate the charging current thru the flat ribbon cable. So check to make sure the ribbon cable is inserted correctly and making all the contacts.
kiev = kenny's innovative electric vehicle

ChristopheFR
Posts: 19
Joined: Sat Aug 11, 2018 1:08 am

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

Tue Nov 27, 2018 2:04 pm

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

redcane
Posts: 35
Joined: Sat Aug 18, 2018 2:21 am

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

Tue Nov 27, 2018 2:15 pm

That message from the icarsoft means it is not connected properly. I see a similar message if I don't have the car on.

ChristopheFR
Posts: 19
Joined: Sat Aug 11, 2018 1:08 am

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

Tue Nov 27, 2018 2:40 pm

I get this message when the car is "READY"

Icarsoft can read 20/24 sections off the OBD.
4 sections cannot be read, like "On board charger" and three other.

kiev
Posts: 858
Joined: Sun May 03, 2015 7:15 am
Location: The Heart o' Dixie
Contact: Website

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

Tue Nov 27, 2018 3:29 pm

ChristopheFR wrote:..
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



Thanks for the pictures, that helps to remember the history.

Charrging is controlled by the EV-EVU.
Your test indicates that the EVSE cable is recognized by the EV-ECU, and it is trying to start the charging session by turning on the relay to supply power to the OBC, but it is not receiving a feedback signal that it requires and turns the relay off. It could be a missing signal from the EVSE or from the OBC.

Since your i909 is not detecting 4 of the CAN Buss devices it would seem to point to either a CAN wiring issue or a blown CAN transceiver chip inside the EV-ECU for that CAN channel of the OBC.

i think there is a data item that you could use the i909 to monitor the signal from the EVSE for inserted regular charging and start of regular charging, would have to scroll thru the menu list to find it under the EV-ECU.

Also on the external connector, E-03, pin 7 should have 12V all the time; pin 2 when the relay comes on; and pin 12 is the CHGP line--not sure if it goes high or low to start charging. Maybe you can repeat your test several time to measure the voltage at these pins, e.g. OFF, READY, and EVSE cable plug-in. Might give some clue.

Also would want to ring out the cable between the EV-ECU and the OBC--check for continuity of the CANH and CANL between those boxes, also check that ground pins have continuity to chassis ground.

p.s. Just for future reference, it is not necessary to have the exact value for the 3 big capacitors, it would be more important to have the same physical dimensions and pins so that they fit inside the box without the need to modify or hammer out the lid for clearance.
Last edited by kiev on Wed Nov 28, 2018 6:01 pm, edited 1 time in total.
kiev = kenny's innovative electric vehicle

skylogger
Posts: 76
Joined: Sun Dec 14, 2014 3:54 am

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

Tue Nov 27, 2018 10:26 pm

There have been three more OBC failures in the last few months. One was from MikeDufty that was mentioned earlier. He took car to dealership, they first swapped out charger, then found that was not the fault, and then finally came back saying there was a wiring fault.

The second OBC Failure was with KT. I pulled the charger from the car and swapped it with one that I had repaired earlier. Once I checked KT's charger, I found the two snubber caps in the doghouse were blown, tested relay and resistors but everything else checked ok. Replaced the blown 20 AMP fuse in the MCU and the snubber caps, put it back in my test IMIEV, and it all works ok.

The Third OBC Failure was sent to a local 3rd party EV repair shop. They purchased a new charger from Mitsubishi, and the owner gave me the broken one. This one had the weird problem of blowing up two of the Uni WA Charging stations, but worked ok on charging at other commercial charging stations. I suspected that since the Uni Charging stations were home made, they were not robust to handle a surge when the charger was first connected. I suspected that the relay that bypassed the resistors in the dog house may have contacts welded closed all the time, so the resistors are bypassed even at first connection. I've pulled this apart, and instead of finding a faulty relay, I find that the 310v 2.2uf X2 Cap in the doghouse is blown. (see attached photo) with this cap blown, The charger was still working well enough to charge from some charging stations, but would actually do some surge damage back to the two charging stations at the Uni.

Image

mikedufty
Posts: 32
Joined: Tue Apr 05, 2016 1:04 am
Location: Western Australia

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

Wed Nov 28, 2018 8:24 am

Still waiting for mine, they say they are now waiting for a fuse, due in December some time. Hope to have it back on the road before the end of the year.
They have never said that there wasn't a problem with the charger, just that they found a wiring problem, which may have been an additional issue.

skylogger
Posts: 76
Joined: Sun Dec 14, 2014 3:54 am

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

Wed Nov 28, 2018 7:16 pm

MIKEDUFFY: Thanks for clarifying that, sorry I did not mean to add misinfo, so the charger may also been faulty. I remember teilling you about the fuse earlier. I think once they swapped chargers they then came across the fact they also had the blown 20amp fuse in the MCU.
Or they replaced the fuse once, blew ithe fuse again because the OBC was faulty, and now have to wait for another fuse to come in.
There are several people waiting on fuses here in Australia. To get KT's IMIEV back on the road, we used a 20amp 1kv fuse and fuse holder out of a solar power system, added pigtail wires and ring terminals, and connected it across where the original fuse location. This is just temporary until the original fuse with tab ends comes in from Mitsubishi. It's a shame they would not let you have the broken OBC Back. I bet the original fault was the usual snubber caps and 20amp fuse, and the wiring fault was introduced.

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