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by DBMandrake
Wed Feb 26, 2020 6:13 am
Forum: Batteries and Battery Management
Topic: Troubleshooting and repair for On-board Charger (OBC)
Replies: 682
Views: 344756

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

Looks like the fuse is finally arriving tomorrow after paying customs charges... in the meantime here is a picture of the potted caps that I meant to post earlier: https://drive.google.com/uc?export=download&id=1dF6n-iTmpeVmSO0Y7Lw6_RU5baNSd5j1 This is neutral cure high voltage high temperature ...
by DBMandrake
Wed Feb 26, 2020 2:59 am
Forum: Batteries and Battery Management
Topic: Fuel gauge vs tortoise
Replies: 33
Views: 16053

Re: Fuel gauge vs tortoise

For what it's worth, I ran battery down to 0 bars and when the turtle came on the bad cell was down to 3.48V, the rest were still at 4.0V. So it seems that the bmu software sets the charge gauge based on the weakest cell, but controls the charger based on the strongest cell. This is essentially cor...
by DBMandrake
Wed Feb 26, 2020 2:40 am
Forum: Batteries and Battery Management
Topic: No Ready and Yellow Light after new 12V?
Replies: 4
Views: 3462

Re: No Ready and Yellow Light after new 12V?

The car definitely won't go into ready unless the RFID tag in the key has been programmed to the car. So if you just bought a random blank key with blank not yet programmed RFID chip and only had the key mechanically cut to fit the lock, that is one of your problems right there. When getting a repla...
by DBMandrake
Tue Feb 25, 2020 9:41 am
Forum: Batteries and Battery Management
Topic: Troubleshooting and repair for On-board Charger (OBC)
Replies: 682
Views: 344756

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

Simon and Kenny, thank you both for such wonderfully detailed information about fixing the OBC and thus making it easier for those of us who will have to face this in the future. :ugeek: Wishing you all the best as the moment of truth arrives today when you fire up the car :!: .... My fuse (I actua...
by DBMandrake
Mon Feb 24, 2020 10:54 am
Forum: Batteries and Battery Management
Topic: Troubleshooting and repair for On-board Charger (OBC)
Replies: 682
Views: 344756

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

The thermal paste arrived today so I have fully re-assembled the OBC unit including sticking the lid down with new silicone. (I ended up just using the same neutral cure stuff I used in the doghouse around the capacitors) So now I'm just waiting for the fuse which I hope will be arriving tomorrow. I...
by DBMandrake
Sun Feb 23, 2020 9:28 am
Forum: Batteries and Battery Management
Topic: Fuel gauge vs tortoise
Replies: 33
Views: 16053

Re: Fuel gauge vs tortoise

So the problem is the weak cell gets down to 3V pretty quick and the computer then shuts down the car to protect it? Essentially yes. Although it won't let it go down as low as 3.0 volts. It will only go down to about 3.6 volts before turtle mode will come on. Can one short out the bad cell? Defini...
by DBMandrake
Sat Feb 22, 2020 3:34 pm
Forum: Batteries and Battery Management
Topic: Fuel gauge vs tortoise
Replies: 33
Views: 16053

Re: Fuel gauge vs tortoise

Car is in Bahamas .. still don't get why one weak cell will suddenly prevent pack from charging more than 25% though. Because all the cells are in series, so the usable capacity of the pack as a whole is limited to that of the weakest cell. Weakest link in the chain. It only takes one faulty cell t...
by DBMandrake
Sat Feb 22, 2020 2:59 pm
Forum: Batteries and Battery Management
Topic: Troubleshooting and repair for On-board Charger (OBC)
Replies: 682
Views: 344756

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

This isn't very pretty but has the measured diode drop voltages on a good waffle plate, with no caps or inductors connected with the fastons. https://i.imgur.com/VbRyfIb.jpg Thanks for that, I've been through and measured all the diodes on your schematic and they all measure healthy. :) I've also c...
by DBMandrake
Sat Feb 22, 2020 12:36 pm
Forum: Batteries and Battery Management
Topic: Troubleshooting and repair for On-board Charger (OBC)
Replies: 682
Views: 344756

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

No just the flying leads from anything on a faston tab, (the leaf charger has a big cap on the fastons and uses the same waffle plate) Ah OK. The board is right out with nothing connected to it, so I'm off to measure it... Interesting that the Leaf has the same waffle plate - since the i-Miev launc...
by DBMandrake
Sat Feb 22, 2020 12:35 pm
Forum: Batteries and Battery Management
Topic: Fuel gauge vs tortoise
Replies: 33
Views: 16053

Re: Fuel gauge vs tortoise

I obtained my 4 second hand cells from the following UK company: https://www.secondlife-evbatteries.com/ev-batteries/yuasa-lev50.html All of them were about 43Ah when discharge tested from 4.1 volts down to 3.0 volts, so better than even the best cells in my pack. I see they are currently out of sto...

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