Don
Site Moderator
Posts: 2857
Joined: Thu May 10, 2012 3:55 pm
Location: Biloxi MS

Re: Now MR BEAN won’t charge!

Thu Jun 21, 2018 3:30 pm

jray3 wrote:the TPMS warning is simply because I’m on my summer set of wheels and didn’t re-synch the sensors after winter.
When you figure out how to reset that (yourself) please post it here - I hope to be needing that info soon

Don
2012 iMiEV SE Premium, White
2012 iMiEV SE, White
2017 Chevy Volt Premier
2014 Ford Transit Connect XLT SWB wagon, 14,000 miles
1979 Honda CBX six into six

jray3
Posts: 1623
Joined: Tue Dec 06, 2011 1:05 am
Location: Tacoma area, WA
Contact: Website

Re: Now MR BEAN won’t charge!

Fri Jun 22, 2018 11:18 am

Indeed Don- doing our own TPMS handshake with a second set of wheels would be a great DIY tool. My dad had the same issue I originally did at a Discount Tire store, with the service manager claiming success on the data link, "just drive around a while for the light to go away"......

Yesterday's main item of business was to remove MR BEAN's battery charger/DC-DC assembly and replace it with a junkyard unit. Still waiting on the correct 400 VDC 20A fuse that goes into the inverter to test charging and DCDC function. Without that fuse, the contactors click as normal and the battery fan blows for a few seconds, then nothing... I have not found a source outside the Mitsu dealer for the the $38 fuse , and ordering on Thursday for "Overnight Shipping" would allow me to pick it up at the dealer on Monday, and of course I should order two... I'm still looking for a properly-rated fuse that I could just put some pigtails on for testing purposes... I'm only dreading the prospect of a VIN-Locked charger.

The component swap was pretty painless, lost only about a cup of coolant. Was able to break loose the hoses by prying with a screwdriver while also pulling at different angles. Main thing to keep in mind is that the J1772 power input wires have no snap-together connector and land inside the charger on three screw terminals. Junkyards will ALWAYS cut that wiring bundle rather than open a sealed unit.

As expected, MR BEAN charges normally on CHAdeMO, and I'm keeping the house battery on an external charger, enabling almost-normal use!

The only errors I pulled from the MUT clone CarSoft i909 besides my four out-of-synch TPMS were as follows:
POA09 DCDC converter fail (oh, hence the red 12V error light)
P1A12 OBC abnormal stop (the charger stopped.. wow)

I found no zorch marks or other signs of failure inside the original charger, and will make it available if a member wants to attempt diagnosis and repair. I haven't pulled the upper boards to get a look at the DCDC converter yet...
2012 i-SE "MR BEAN" 102,600 miles
2000 Mazda Miata EV, 78 kW, 17 kWh
1983 Grumman Kurbwatt EV,170 kW, 32 kWh
1983 Mazda RX-7 EV 43 kW 10 kWh
1971 "Karmann Eclectric" EV 240 kW 19 kWh
1965 Karmann Ghia Cabriolet

jray3
Posts: 1623
Joined: Tue Dec 06, 2011 1:05 am
Location: Tacoma area, WA
Contact: Website

Re: Now MR BEAN won’t charge!

Fri Jun 22, 2018 2:10 pm

Here's the spec sheet for our 20A fuse under the inverter inspection cover. Still haven't found an online vendor.
https://www.pecj.co.jp/fuse/files/PEC_EVFG72_en.pdf
2012 i-SE "MR BEAN" 102,600 miles
2000 Mazda Miata EV, 78 kW, 17 kWh
1983 Grumman Kurbwatt EV,170 kW, 32 kWh
1983 Mazda RX-7 EV 43 kW 10 kWh
1971 "Karmann Eclectric" EV 240 kW 19 kWh
1965 Karmann Ghia Cabriolet

kiev
Posts: 926
Joined: Sun May 03, 2015 7:15 am
Location: The Heart o' Dixie
Contact: Website

Re: Now MR BEAN won’t charge!

Fri Jun 22, 2018 4:27 pm

jray3 wrote:
...
I found no zorch marks or other signs of failure inside the original charger, and will make it available if a member wants to attempt diagnosis and repair. I haven't pulled the upper boards to get a look at the DCDC converter yet...


i'm gonna speak for Paul (Piev), and say that he and i will take a look at fixing it for you. He is also down here in the huntsville, alabama area and we have 4.125 mievs between the both of us. It sure seems like there is a rash of failed chargers here lately... we need to figure out what's going on with these thangs?
kiev = kenny's innovative electric vehicle

jray3
Posts: 1623
Joined: Tue Dec 06, 2011 1:05 am
Location: Tacoma area, WA
Contact: Website

Re: Now MR BEAN won’t charge!

Fri Jun 22, 2018 9:10 pm

Thanks Kenny, I was hoping you’d pipe up. Will start looking for the right box.
I’m happy to report “Mission Accomplished” on the charger/DCDC swap. With the correct fuse not arriving till next week (only one in the USA dealer inventory system), I routed that juice through a spare solar combiner box with two 10A 600 V fuses in parallel.
DCDC and charger have been working normally for two hours so far. Hope this report ain’t premature!

Takeaways:
-NO VIN LOCKING on the charger.
-Coolant system appears to be self-purging of air. I lost little coolant with no precautions taken, it took as much in make-up water, and the bubbles worked out quickly.
-DCFC can save your bacon in the event of a charger failure.
-Remember to fully charge the 12V battery in the event of DCDC failure. I drove 56 miles without it (with two DCFC sessions, as the charger failed at 1/3 SOC).
-The vacuum pump stopped running first as 12V voltage dropped, and braking was not noticeably affected, probly because I still have very little free play in the brakes and not much pedal travel required.

PS: Yep, one full normal recharge completed and all is well.
2012 i-SE "MR BEAN" 102,600 miles
2000 Mazda Miata EV, 78 kW, 17 kWh
1983 Grumman Kurbwatt EV,170 kW, 32 kWh
1983 Mazda RX-7 EV 43 kW 10 kWh
1971 "Karmann Eclectric" EV 240 kW 19 kWh
1965 Karmann Ghia Cabriolet

jray3
Posts: 1623
Joined: Tue Dec 06, 2011 1:05 am
Location: Tacoma area, WA
Contact: Website

Re: Now MR BEAN won’t charge!

Tue Jun 26, 2018 10:56 pm

Today I received that pesky 20A 400V fuse under the inverter inspection cover that pops when there is a charger or DCDC fault. It is part #2759 from the mfr; PEC, but is stocked as “FUSE, MOTOR” Mitsubishi part #9499A656. Thanks go out to Concord Mitsubishi of Concord, CA for shipping it directly to me. MR BEAN is back to 100% after a quick installation. (I ran the last several days and about 300 miles with some make-do solar array fuses spliced in its place!)
2012 i-SE "MR BEAN" 102,600 miles
2000 Mazda Miata EV, 78 kW, 17 kWh
1983 Grumman Kurbwatt EV,170 kW, 32 kWh
1983 Mazda RX-7 EV 43 kW 10 kWh
1971 "Karmann Eclectric" EV 240 kW 19 kWh
1965 Karmann Ghia Cabriolet

sandange
Posts: 907
Joined: Thu Jul 05, 2012 2:21 am
Location: Quebec, Canada
Contact: Website

Re: Now MR BEAN won’t charge!

Wed Jun 27, 2018 5:45 am

Thanks for taking the time in investigating & sharing this information with the forum,
This is hitting the nail on the head in addressing a major reoccurring failure that has shown up in more & more Mievs
as they start to rack up the miles.
The blown fuse, in other instances, has indicated a serial number locked out unit failure that made the repair $ costs estimates
more than the resale value of the vehicle rendering it disposable.
Should your findings here solve how to work out the serial number lock outs or discover a cost effective repair solution,
you would bring many "otherwise considered" scrap i Mievs" back to useful service status.
Your expertise in very much appreciated
Thank you for showing us the way.
Tesla Model 3 SR+, 2019
Previous EVs
Puey Bluey 2014 Miev
200,000 km , 124.000 miles.
Blackie - 2012 ES Miev 2 years - 67,000 km / (41,630 miles)
http://thecordstead.blogspot.ca/

Don
Site Moderator
Posts: 2857
Joined: Thu May 10, 2012 3:55 pm
Location: Biloxi MS

Re: Now MR BEAN won’t charge!

Wed Jun 27, 2018 6:24 am

X2! - Thanks for all your work. Knowledge like this is why we all get together here and it's a 'big deal' when someone comes up with things which can benefit us all

Don
2012 iMiEV SE Premium, White
2012 iMiEV SE, White
2017 Chevy Volt Premier
2014 Ford Transit Connect XLT SWB wagon, 14,000 miles
1979 Honda CBX six into six

coulomb
Posts: 167
Joined: Sun Jun 10, 2018 8:32 pm
Location: Brisbane, Australia

Re: Now MR BEAN won’t charge!

Fri Jun 29, 2018 7:06 pm

jray3 wrote:Here's the spec sheet for our 20A fuse under the inverter inspection cover. Still haven't found an online vendor.

It's an unusually compact fuse for the rating. It's like a 3AB ceramic fuse with tags, but slightly larger diameter. I believe that PEC might stand for Panasonic Electronic Components, in case that helps any. [ Edit: this is WRONG. See my correction. ] It agrees with "Country of origin: Japan".
Last edited by coulomb on Tue Jul 03, 2018 5:27 pm, edited 1 time in total.

coulomb
Posts: 167
Joined: Sun Jun 10, 2018 8:32 pm
Location: Brisbane, Australia

Re: Now MR BEAN won’t charge!

Fri Jun 29, 2018 7:12 pm

kiev wrote: It sure seems like there is a rash of failed chargers here lately... we need to figure out what's going on with these thangs?

My guess is electrolytic capacitors coming to their end of life, and going high internal resistance and/or low capacity.

Some photos I've seen have the plastic no longer covering the tops of the capacitors (so that the full diameter of aluminum is visible from above), which suggests a lot of heat. Electrolytics hate heat; it ages them. Hopefully, it won't be like the Elcon EV chargers, where electrolytic capacitors are protecting the switching MOSFETs or IGBTs.

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