Troubleshooting and repair for On-board Charger (OBC)

[kiev]

Howdy Domen,

Thank you for the follow-up of the details, your english is great no problem. Enjoy your car, EVs are fun to drive.

[Dala]

Hi all,
I posted a few weeks about a 2011 Peugeot Ion with a faulted OBC. I have now replaced the V110 2011 Charger, with a V100 2014 unit. It was not so straightforward, the HV connector, 12V DC/DC connector, and water coolant lines did not match up, but I got creative and made it fit. Happy to report that the newer charger works

Old:


New:


Will post a video shortly...

[Dala]

And here is the video on the repair, as promised

https://youtu.be/31RpM-_xhpQ

[jray3]

Congratulations and thanks to Dala! Your candor and genuine enthusiasm are greatly appreciated.
Why would they supercede version 110 with version 100?

[Dala]

Hah, no clue

[Mucker]

Hey People,

I tried to repair my third OBC, but stupid like people sometimes are, i reversed the L and The Y1 and then the ac-circuitbreaker B16 shuted the device of.
Since that i am unable to charge and at this time not sure anymore, how exactly the situation was, when i plugged the AC-cable in again.

The Situation now is that i have disassambled the waffleplate to check, if I crashed it.

On that picture it should be the pins 6 and 7 on the right side, which i reversed.
https://drive.google.com/file/d/1tHilCx ... OVV85/view

can someone give me advice, on which pins with a multimeter or this LCR-T4 https://www.ebay.de/itm/232563927160?ha ... SwKtlZlkiL i need the measure what, to find out, if the waffle plate is faulty or not?

If it should be good, i will reassamble it and then try step by step fixing other components.

At this point i found a crashed resistor, the big one with 4,9 Ohms made of ceramic.
All the caps are often faulty are good (2,2uF, both 1nF) because i replaced them before reversing the wires.
Now i checked them again and the relay also is fine.

While checking the relay i'm not sure, if i killed D301. What should the multimeter say in the different directions, if it is fine?

It is only the bottom board which is faulty.
The top board in connection with another bottom board works.

And Is there a way to post pictures here?

Best thanks for your support.

[kiev]

Where is AC circuit breaker B16 located? i'm not familiar with B16 and don't understand.

If you have tried 3 OBCs in this same car, then i suspect you have an external problem such as with the EVSE or AC Mains voltage supply or wiring, etc. You will need to get to the root cause of that problem before blowing up additional OBC units and parts. You will need to exercise extra caution and attention to details so as to not cause new problems, some of which are irreversible and not easily repaired, such as the waffle plate.

What country are you located and what is your best language? Maybe one of the other miev forums would have someone that could help you locally.

What is your knowledge, skills and abilities with electrical and electronics troubleshooting and repairs? What electrical tools do you have and your ability and skill to understand how to operate and measure with them?

There is much information in this forum thread to assist someone to make some repairs, but it requires a certain level of electronics knowledge and abilities. Hopefully you can get the necessary information and make a successful repair, but i am very limited in my free time right now.

[JoeS]

...And Is there a way to post pictures here?...

We have a thread dedicated to this topic - you might try this:
http://myimiev.com/forum/viewtopic.php?p=39027#p39027

[coulomb]

On that picture it should be the pins 6 and 7 on the right side, which i reversed.

Ah. That means that a pair of diodes would be placed across each of the two transformers' outputs. It's hard to say what this would have done; it certainly will have stressed the diodes, and possibly also the IGBTs driving the tranformers.

can someone give me advice, on which pins with a multimeter ... i need the measure what, to find out, if the waffle plate is faulty or not?

Find pairs where there are single diodes between them. For example, N0 to T7. The diodes should show about 0.3-0.4 V drop with the positive lead on the anode (the triangle end) and the negative lead on the cathode (bar end). It should read open circuit (OL or similar) with the leads reversed.

Unfortunately, there is a connection in the middle that is not accessible. So you have to get creative. You should see no conductivity in either direction from T7 to T8 or T6 to T5 (these are the most likely problem areas). Then T7 to T6 you should see two diode drops (0.6 to 0.8 V one direction, infinite the other), and similarly T7 to T5, T8 to T6, and T8 to T5, N0 to P0, N0 to T6 and T5, T7 to P0 and T8 to P0.

Test the IGBT back diodes; if these are normal 0.3-0.4 V drops, they are likely OK. Like diodes, they should be infinite in the other direction. Example: single drops 15/16 to T4, double drop 16/15 to P. Gate to emitter should read as 1kΩ in both directions (use the resistance range, not diode range for this).

[Mucker]

Hey People thank you for your Advice.

I measured with the LCR T4 Mega:

N0 to T7 Uf=474 mV C=474 pF
N0 to T8 Uf=474 mV C=471 pF

T7 to T8 Uf= / mV C=260pF

T6 to T5 Uf= / mV C=300pF

T7 to T6 Uf=945 mV C=322pF
T7 to T5 Uf=945 mV C=330pF

T8 to T6 Uf=941 mV C=324pF
T8 to T5 Uf=941 mV C=330pF

N0 to P0 Uf=945 mV C=492pF
N0 to T6 Uf=945 mV C=371pF
N0 to T5 Uf=945 mV C=381pF

T7 to P0 Uf=945 mV C=407pF
T8 to P0 Uf=945 mV C=412pF

15/16 to T4 Uf1=527pF, Uf2=528pF

So the Waffleplate seems to be okay, right?