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

Tue Sep 01, 2020 9:40 am

Hello again,

I was not at home the last few days and I wanted to take the measurements for you. After turning the power supply on, I got the same problem as before. I did not even touch the boards and now they do not work anymore.

IC318 still measures nothing between pin 4 and pin 5. You mentioned to measure the input voltage on pin 1 but the datasheet states to me it is a NC pin and there is no voltage present there. Is IC318 a TI TL431-Q1?

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

Tue Sep 01, 2020 10:49 am

Yes it is, sorry i told you the wrong pin--should be pin 3 on the 5-pin package. The input voltage will be on
pin 3.
Last edited by kiev on Tue Sep 01, 2020 5:41 pm, edited 1 time in total.
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zetafunction
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Re: Troubleshooting and repair for On-board Charger (OBC), DC-DC Converter

Tue Sep 01, 2020 10:54 am

Between pin3 and pin5 there is also no voltage at all

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

Tue Sep 01, 2020 11:09 am

What about on the capacitors listed previously--are they zeroed out too?

Maybe the voltage is not reaching the bottom board thru the ribbon cable--check the ribbon connection.

i will check if i have a listing of the voltages on each pin of the ribbon cable.

The issue could be on the top board power supplies created from the 12V input power?

Is there anyway to determine which +12V supply is not drawing current? CN101 pin 7 or pin 12, or how much is being drawn on each of those?

Here's some notes i had about the CN1 flat ribbon cable, not double checked:

pins 1-4: Ground, bottom of C841

pins: 16,18,20,31,33,40, 47-50 : Grounds

pins 5-8: +12V nominal, top side of C841

pins 12-13: 5V

pins 22-24: 5V to PC305

pin 25: RLY1 return
pins 26-29: RLY1 5V supply

pins 34-37: 16V nominal

pins 43-46: 5V
Last edited by kiev on Sun Oct 04, 2020 9:29 am, edited 2 times in total.
kiev = kenny's innovative electric vehicle

zetafunction
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Joined: Fri Jul 31, 2020 4:26 pm

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

Tue Sep 01, 2020 11:16 am

C845... 0V
C841... 11.72V
C369... 0.72V

I think the 12V are reaching the board, since C841 is powered up

kiev
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Two 12V Supplies on top board, CN101

Tue Sep 01, 2020 11:42 am

There are two 12V supplies to the top board of the OBC on CN101.
CN101 pin 7 is a Hot All The Time 12V Input supply.
CN101 Pin 12 is the Switched 12V supply labelled as "ICGC" on the board.

Hot All the Time:
From this Hot All The Time 12V, there is a 5V regulator on the top board, IC710, that creates a HAAT 5V feed on pins 22-24, which goes to PC305, an optocoupler that reports back on pin 21 the presence of the AC Input voltage downstream of the AC relay.

Switched:
The 12V on pins 5-8 of CN1 that shows up on C841 for the Transformer T302 circuit is coming from the Key ON Switched 12V feed from pin 12 of CN101.

The AC coil relay 5V supply on pins 26-29 is created from the Switched 12V supply.
Last edited by kiev on Sun Oct 04, 2020 10:33 am, edited 2 times in total.
kiev = kenny's innovative electric vehicle

zetafunction
Posts: 35
Joined: Fri Jul 31, 2020 4:26 pm

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

Tue Sep 01, 2020 12:15 pm

Pin 13 of CN1 only outputs 1.92V but all other Pins seem to be fine.

The input on pin 7 consumes absolutely nothing, pin 1 consumes 125mA.

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

Tue Sep 01, 2020 1:14 pm

Your picture on page 53, looks like pin 7. Check resistor R748, there should be 5V there when powered up.

check you PM if you want to send me an email.
Last edited by kiev on Tue Sep 01, 2020 7:18 pm, edited 2 times in total.
kiev = kenny's innovative electric vehicle

zetafunction
Posts: 35
Joined: Fri Jul 31, 2020 4:26 pm

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

Tue Sep 01, 2020 6:42 pm

The 5V on R748 are measuring out fine

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

Tue Sep 01, 2020 7:24 pm

it looks like it is all around the switching of the transistor. The source comes from the top board 12V on pins 5-8.

i had thought ic318 may have come from one of the 5V supplies, but it also comes from the switching.

You might be able to trigger a response to come on by using either cold spray or hot air around the ceramic capacitors, e.g. C846 (meas. 884nF), and all those around ic702 in the power supply circuit, e.g. the timing cap on pin 7.

ICs won't heal themselves if they fail, but ceramic caps can crack and short out intermittently, especially with temperature changes. And try the Chips also, maybe there is an internal fault sensitive to temperature.
kiev = kenny's innovative electric vehicle

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