Jokerrevda
Posts: 12
Joined: Sun Jun 19, 2022 10:40 pm

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

Помимо фавельной пластины, из строя вышли несколько конденсаторов, которые стояли на другой плате. Их заменил на такие же.
У нас нету свалки машин. И запчасти продают только на разборках. И некоторые продавцы завышают цену на товар.

Google Translate -
In addition to the waffle plate, several capacitors that were on another board failed. They were replaced with the same ones.
We don't have a car dump. And spare parts are sold only at disassembly. And some sellers inflate the price of the goods.
Jokerrevda
Posts: 12
Joined: Sun Jun 19, 2022 10:40 pm

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

Ещё такой вопрос , вы написали транзисторы, не могли бы вы написать марку и модель транзисторов? Так как я в этом плохо понимаю. На счёт эпоксидной смолы, сегодня буду пробовать одну смывку, если поможет покажу результат.

Google Translate -
Another question, you wrote the transistors, could you write the make and model of the transistors? Because I don't understand it very well. At the expense of epoxy, today I will try one wash, if it helps I will show the result.
kiev
Posts: 1778
Joined: Sun May 03, 2015 7:15 am
Location: The Heart o' Dixie
Contact: Website

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

Unfortunately we don't know the part number for the transistors in the epoxy; the few that have been uncovered were found to have been etched to remove the marking. But if you can expose the part down to the green board then we could probably find a replacement part that fits the solder pattern.
kiev = kenny's innovative electric vehicle
coulomb
Posts: 325
Joined: Sun Jun 10, 2018 8:32 pm
Location: Brisbane, Australia

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

Jokerrevda wrote: Wed Jun 22, 2022 5:00 pm Помимо фавельной пластины, из строя вышли несколько конденсаторов, которые стояли на другой плате. Их заменил на такие же.
У нас нету свалки машин. И запчасти продают только на разборках. И некоторые продавцы завышают цену на товар.
Google translation (two posts):

In addition to the [ waffle ] plate, several capacitors that were on another board failed. They were replaced with [ similar ] ones.
We don't have a car dump. And spare parts are sold only at disassembly. And some sellers inflate the price of the goods.


Another question, you wrote the transistors, could you write the make and model of the transistors? Because I don't understand it very well. At the expense of epoxy, today I will try one wash, if it helps I will show the result.
Mucker
Posts: 7
Joined: Fri Feb 18, 2022 7:02 am

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

Why do you suspect the diode? If it were shorted then the reading would not show 60 Ohms; if it were open it would show the 60 Ohms, then it would not prevent the relay from operation, but it would lack the freewheeling diode protection when commanded to OFF.

To test the relay you must put +5V at the end with the "bar" line, and return on the opposite end; this is in the blocking direction for a diode, it should not conduct thru the diode. See the picture in post #1 of this thread.
[/quote]

Hey Kenny,

I reversed the lines to test the relay and then the diode smoked a little bit and became hot.

I tested the OBC now without changeing or checking the Diode after replacing the 4,7 ohms resistor and it was not working.
The fan starts for short, the LEDs in the AC-cable are going to charge and after a few seconds the are green for finished again.
The relay doesn't close and there are no OBD-faultcodes left now.

So I would test D301 in the Future.

But does anyone has another Idea, why it is not working?

And Kenny would you like to try a paid try to repair this, if I send this to you.
Because now I have no Idea left, except the diode.
And I think your chances are much better than mine.

Or does someone has an OBC plate or a whole OBC to buy.
JohnnySK
Posts: 5
Joined: Thu Jun 23, 2022 1:06 pm

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

Hi frends.
I have simmilar problem with charging with OBC but I checked everything desribed..
OBD2 says U1111 and U1116
I checked all plates of charger and everything looks good. I tested connect AC and relays at front swich on cooling and everyting as normal..
1. Relay at front switch
2. Display start to show battery status
3. Fan for battery cooling spinning
4. AC goes to RC filter relay is switched
5. AC is on board of AC charger..
6. DC 345V at pins from charger to next box
7. High voltage fuse is ok, and voltage is there.
8. Charging of 12V battery starts ...14.4V
aaand Orange car sign with (!) appear on display and all relays drops and charging not start..

What I should to check next ? I don't know what now..

Thank you for any help..
kiev
Posts: 1778
Joined: Sun May 03, 2015 7:15 am
Location: The Heart o' Dixie
Contact: Website

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

Mucker wrote: Thu Jun 23, 2022 10:57 am ...
I reversed the lines to test the relay and then the diode smoked a little bit and became hot.
Oh i'm sorry to hear, that's not good.
i wish that you would have mentioned this before, and then i would have recommended to replace the diode.

Now i suspect that both the diode and the relay are damaged. And both should be replaced before doing any testing.
I tested the OBC now without changeing or checking the Diode after replacing the 4,7 ohms resistor and it was not working.
The fan starts for short, the LEDs in the AC-cable are going to charge and after a few seconds the are green for finished again.
The relay doesn't close and there are no OBD-faultcodes left now.
This is how the OBC acts when the relay does not close and let the AC flow into the waffle plate, or if the AC monitoring circuit is not reporting back from the bottom board to the upper control board.

i think you could replace the diode, or take the board to a tv/cell phone/electronics repair shop and let them do it. If possible it would be good if you could then properly connect the leads to test the relay. If the relay works good, then with a new diode i would expect you could charge successfully.
kiev = kenny's innovative electric vehicle
kiev
Posts: 1778
Joined: Sun May 03, 2015 7:15 am
Location: The Heart o' Dixie
Contact: Website

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

JohnnySK wrote: Thu Jun 23, 2022 2:02 pm Hi frends.
I have simmilar problem with charging with OBC but I checked everything desribed..
OBD2 says U1111 and U1116
I checked all plates of charger and everything looks good. I tested connect AC and relays at front swich on cooling and everyting as normal..
1. Relay at front switch
2. Display start to show battery status
3. Fan for battery cooling spinning
4. AC goes to RC filter relay is switched
5. AC is on board of AC charger..
6. DC 345V at pins from charger to next box
7. High voltage fuse is ok, and voltage is there.
8. Charging of 12V battery starts ...14.4V
aaand Orange car sign with (!) appear on display and all relays drops and charging not start..

What I should to check next ? I don't know what now..
Those DTCs will prevent charging.

What is the age and condition of your 12V battery?

If it is old, weak or worn out, then it could be causing CAN buss errors that you are seeing on the DTCs.

If the CAN buss is not working properly, then lack of communication between the OBC and the EV-ECU will prevent charging.

Your measurements seem to indicate that the OBC is okay, which is a good thing. Fix the CAN errors and all should be good.

Also Inspect the CAN lines for insect or rodent damage also, under the rear seat and back to the OBC, etc.
kiev = kenny's innovative electric vehicle
JohnnySK
Posts: 5
Joined: Thu Jun 23, 2022 1:06 pm

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

kiev wrote: Thu Jun 23, 2022 2:45 pm
Those DTCs will prevent charging.

What is the age and condition of your 12V battery?

If it is old, weak or worn out, then it could be causing CAN buss errors that you are seeing on the DTCs.

If the CAN buss is not working properly, then lack of communication between the OBC and the EV-ECU will prevent charging.

Your measurements seem to indicate that the OBC is okay, which is a good thing. Fix the CAN errors and all should be good.

Also Inspect the CAN lines for insect or rodent damage also, under the rear seat and back to the OBC, etc.
I changed 12V battery 2months ago.
I have OBDlink LX only.. It is enough for remove errors ? (Can you recommend some app, please ?)
Already checked cables around OBC , between OBC and rear bumper too.. All on place, without demage.. connectors maximaly pushed together..
I will check cables under rear seat tomorow.. thanks for suggestion.
And I will do one more measurement.. Disconnect of high-voltage cable from OBC to Inverter .. and I will check what will happend.. if I still will have 345VDC on pins from OBC etc. Because I measured it with all cables connected, directly on board.
kiev
Posts: 1778
Joined: Sun May 03, 2015 7:15 am
Location: The Heart o' Dixie
Contact: Website

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

i'm not sure removing the HV cables and trying to charge would be a good idea. i could never recommend someone to try that. What would it prove, how would it help determine the problem?

The OBC won't turn ON without the HV battery connected. The control board monitors the voltage and current, and i don't believe it would activate charging with the "load" missing. And if it did, what would that prove versus the risk of damaging something.

If you don't have a DTC for the OBC, then it could be due to the defective CAN signal, which could be masking the HV error (!) that is showing on the dash.

A better test would be to check the diode drops in the waffle plate, specifically the lower right corner H-bridges. The AC rectifier and PFC seems to be working from your measurements, but possibly the transistors in the waffle plate are damaged and no switching to the transformers is taking place, just a possible cause.

i don't know if any of the apps can clear error codes; i use an i909 from iCarsoft but it is older and there may be newer and better versions, some maybe with phone apps, e.g. Launch seems to make the i909 and they have many different models.

i bought 4 new batteries during the pandemic and they were all crap. They read full voltage but had no capacity and were somewhat sulfated and needed long slow charging to restore. So just because it's new doesn't mean it is good. Give it a good charge and try again to see if the errors go away. The CAN errors will usually clear on their own given a strong 12V battery. If the new battery has set for 2 months without charging then it has sulfated and lost capacity.
kiev = kenny's innovative electric vehicle

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