hubermatos wrote:...They pack is ok, it was a bit smelly, like burned electric parts, but we found nothing suspicious.
You never answered my previous question about the swapping of the EV-ECU, so what we got here is a failure to communicate. Maybe gooogle translate is needed here, what is your preferred language?
With the old EVECU the main contactors were not being energized, but with an EVECU swap from the working car, then the car went to READY? [That would mean the contactors were getting energized properly].
You then ordered a used ECU from Poland which did not energize the contactors, but did you test it in the working car and get READY? The unit from Poland may be defective but you can't know for sure without a test to verify it is known to be good. There will be a VIN error when trying to do a swap that will likely prevent a car from going to READY; the EVECU is not swappable without reprogramming of the VIN.
Concerning the pack inspection:
Did you inspect the pre-charge resistor near the main contactors? There has been at least one reported case of failure of that resistor, and it would surely smell like burned electric parts if it overheated.
What about the cooling fan inside the pack, not sure if it has brushes or not, but motor brushes can wear and cause an overheating condition and smelly burnt wire too.
Another item might be the coils of the contactors. They should be rated to handle continuous operation but you never know.
The contacts of the contactors provide an ultra-low resistance path when ON. It would be difficult to measure that low without special equipment, but if the surface was damaged it could affect the voltage to the big condenser in the MCU.
If something overheated to cause a smell, then look for discolored wiring also.