coulomb
Posts: 114
Joined: Sun Jun 10, 2018 8:32 pm
Location: Brisbane, Australia

Re: Help installing a used charger

Sun Aug 12, 2018 4:42 am

1pk wrote:So I have the "new" charger from a wrecked 2013. So of course I popped it open and here is what the inside looks like

I note that there is no dog house on either the upper or middle boards.

As alluded to before, no waffle plate™. The three large capacitors also have no dog house, and they have their plastic extending over the top of the aluminium case. There seems to be a lot less wiring clutter, and possibly fewer magnetics. It's really neat inside, compared to the older models.

1pk
Posts: 70
Joined: Thu Jul 10, 2014 7:34 am
Location: Chemainus, BC

Quick help with charger replacement please

Sun Aug 12, 2018 2:16 pm

This is the high voltage cable from the charger to the MCU . Is this silver sheathing important? It doesn't exist on the 2012

Image

If it has a purpose then I need advice as to how to proceed because my plan is to cut it.

Also I have to figure out the polarity of the HV cables.

the 2012 charger HV cables are labeled L and R which is great.

Image

but the new one is labeled P and N? Is there a convention to relate these two labeling methods?

Image

And I can't tell from the MCU which is which. This is under the small panel. The HV cables come in directly under the 2 connections in this image.

Image

I've got all the other connections worked out, and as soon as I can solve the these issues with the HV cables I can hook it all up and test it.

kiev
Posts: 815
Joined: Sun May 03, 2015 7:15 am
Location: The Heart o' Dixie
Contact: Website

Re: Quick help with charger replacement please

Sun Aug 12, 2018 4:47 pm

1pk wrote:This is the high voltage cable from the charger to the MCU . Is this silver sheathing important? It doesn't exist on the 2012

It is likely for abrasion and cut resistance, although it might provide a minimal amount of EMI noise filtering, but the spacing of the webbing is too coarse for any real EMI control.

It looks like it bolts to the case so it could be removed and re-used.

Also I have to figure out the polarity of the HV cables.

the 2012 charger HV cables are labeled L and R which is great.
The R and L are the color codes, for RED and BLACK, which is the color of the tape wrapped around the orange jacket. The RED is the Positive (+) high voltage output that would connect to the Pack (+) in the MCU.

but the new one is labeled P and N? Is there a convention to relate these two labeling methods?
This is for POSITIVE (+) and NEGATIVE (-), and would be equal to the R and L.


And I can't tell from the MCU which is which. This is under the small panel. The HV cables come in directly under the 2 connections in this image.

Here is the 2012 polarity marked for the MCU with the cover open. If you have a voltmeter that will read up to 400VDC, then you could turn the key to READY and verify the polarity at those connections in the MCU. The Positive from the charger connects to the fuse, the Negative bolts directly to the (-) buss bar.

Image


I've got all the other connections worked out, and as soon as I can solve the these issues with the HV cables I can hook it all up and test it.


Here it is marked the connection from the OBC to MCU at the fuse, the Positive or Red wire, will attach to the fuse.

Image
kiev = kenny's innovative electric vehicle

1pk
Posts: 70
Joined: Thu Jul 10, 2014 7:34 am
Location: Chemainus, BC

Re: help locating a used on board charger

Sun Aug 12, 2018 8:22 pm

It has been a while since I've seen this!

Image

Thanks Kiev!!!!! I'm very relieved. Its been charging for 3 hours now and it's almost done.

I need to improve some of the connections and make them more permanent but now at least we know it works and at least a 2013 charger can be fitted into our cars.

A huge Thank You to everyone who helped out.

Pete

jray3
Posts: 1585
Joined: Tue Dec 06, 2011 1:05 am
Location: Tacoma area, WA
Contact: Website

Re: help locating a used on board charger

Mon Aug 13, 2018 9:43 am

1pk- congrats on the repair! Which yard in Tacoma crushed a car after radio removal only? A very nice black car was auctioned recently here and I haven't found where it landed. If you were after the blue n white car at B&R Auto Wrecking, take some solace that I got basically EVerything BUT the motor before it was crushed...
2012 i-SE "MR BEAN" 96,000 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

1pk
Posts: 70
Joined: Thu Jul 10, 2014 7:34 am
Location: Chemainus, BC

Re: help locating a used on board charger

Mon Aug 13, 2018 10:52 am

Thanks Jray. It feels good to have it back on the road.

It was B&R in tacoma. I’m glad you got to it. It seemed unlikely that they would not salvage it before crushing. Is that the inverter you used?

I’m hoping that the new inverter design was to make it more robust.

jray3
Posts: 1585
Joined: Tue Dec 06, 2011 1:05 am
Location: Tacoma area, WA
Contact: Website

Re: help locating a used on board charger

Mon Aug 13, 2018 3:45 pm

Yes, that's the charger that I transplanted. The motor and inverter are still in the B&R warehouse (well, at least I saw the motor). They had no clue on component naming, so I negotiated down the charger price. True-to-form, their manager sits behind a one-way mirror and that ass behind the glass would never come out and speak to me in over 18 months and $2k of buying parts off of that car. He crushed it right after I offered to buy all that remained, but he wouldn't budge from a $4k price!!
I worked in a wrecking yard during college- and those boys are a special breed..... :roll:
2012 i-SE "MR BEAN" 96,000 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

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