Page 64 of 64

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

Posted: Mon Feb 22, 2021 7:50 am
by kiev
Sounds like you have damage on both the AC input side and the DC output section, that's somewhat of a puzzle as it's usually one side or the other, not so much both.

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

Posted: Mon Feb 22, 2021 11:38 am
by Lic
I don't see 9,6Om resistance between points N00 and waffle board N contact, so one or both 4.7Om resistors are dead.
Image

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

Posted: Mon Feb 22, 2021 12:36 pm
by kiev
WOW! Never seen so much smoke damage before, that thing really exploded.

There is discoloration on one of the white ceramic resistors--that one may be cracked.

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

Posted: Mon Feb 22, 2021 3:08 pm
by coulomb
kiev wrote:WOW! Never seen so much smoke damage before, that thing really exploded.

It looks to me more like an arc flash than a component burning. The fibreglass of the printed circuit board will have been damaged by carbonization, which is bad news as it is conductive. It will be difficult to clean all the blackened material so that it is safe for high voltage DC operation again. Every last spec has to be removed, and a good conformal coating applied. It may not be practical to repair that board, depending on the damage.

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

Posted: Mon Feb 22, 2021 3:10 pm
by Lic
I was able to reach resistors contacts, so resistor with discoloration is fine, other one (P10K fuse) is dead. I don't want to remove waffle board (but I can - it just takes time), so I will try to reach resistor contacts by soldering iron or may be I will try to cut bad resistor to reach his legs. Also I checked diode voltage drop and it looks fine.

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

Posted: Mon Feb 22, 2021 7:13 pm
by kiev
oh yes i agree arc flash is more accurate description.

You probably should check or replace the AC relay since the ceramic resistor fused. i'm guessing maybe for some reason that relay opened while charging--that might explain the damages.

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

Posted: Tue Feb 23, 2021 11:42 am
by Lic
AC relay is working fine. I checked several times.