Troubleshooting and repair for On-board Charger (OBC)

[kiev]

i find that using an internet web search can answer numerous questions about things i don't know,

https://duckduckgo.com/?q=OBDII+dongle& ... &ia=images

Here's one i like and use to read the DTC trouble codes stored in the car's memory, using an android phone,

http://www.scantool.net/scan-tools/smar ... nk-lx.html

There are also scan tools that have cables and plug in to the OBDII port to scan and read the codes and data.

[disar]

Hi!
I'm trying to fix OBC 2013+ but I dont have diagram. I have problem with some connections:









I don't know where connect red"A" from the picture. I thinhk that it should be connected with D510 from red block 3 but it isn't, Maby connection is burned?

Next question is about red "B" connection. Yellow Mosfet no.1 from the picture is connected with Yellow mosfet no.3. Is it correct? Mosfet no.2 isnt connected with mosfet no.4....

[coulomb]

I'm trying to fix OBC 2013+ but I dont have diagram.

This must be the "post Waffle Plate™" design, which we unfortunately know much less about.

[kiev]

Did you desolder some of the mosfets, e.g. Q103-104-105-106 ? It looks like solder is missing

Those 4 fets make up an H-bridge that is switching the DC thru that big transformer in the FR corner of the OBC.

[disar]

I desolder it for measuring time. All 4 fets was damaged, so there are new.

Thanks for diagram! Do you how these fets are control by?

I think that:
Q501 controls Q104
Q502 controls Q105
Q503 controls Q103
Q504 controls Q106

Am I right?

[kiev]

Yes the FETs are controlled in pairs (cross pairs of the H-bridge) so only the upper on one side and the lower on the other side are ON at the same time. This is done by control of the Gate Drive transformers.

Measure for continuity between the Source and the Drain of the neighbor FETs to fill in the layout of my diagram, (i'm guessing that Q105 and 106 will be the top and bottom on the same side of the H)

The trace from under D510 does appear to be a different color--was the green solder mask removed or burnt off?

With all 4 FETs blown then there is something else damaged or at fault that needs to be found.

Go take a look at the thread about these OBC2, you may want to post there to keep it all together,
https://myimiev.com/forum/viewtopic.php?p=44637#p44637

[Hayo]

i started a sketch to figure out how the signals are sent to the waffle plate.

I am trying to repair my 2011 OBC with blown 4.7 ohms resisters (replaced relay, AC filter and snubber caps also).
During repair I damaged a the small capacitor, that's connected between pins 23/24 of the right waffle plate connector. I think, it's the very same, kiev has drawn in his sketch, with no further annotations to it.



I would say, it's a filter for high frequency noise, not sure if it's really necessary.

Has anyone an idea, what size that capacitor has? The are no markings on it.
I would maybe replace it with a through hole type soldered over pin 23 and 24.

The white wire I added is repair due to some unsoldering damage.

Your help is much appreciated!
Hayo

[kiev]

@ Hayo,
You should give thanks to Jay for the failed OBC used for all of these circuit tracings.

i removed the 10 Ohm resistor to open up the path thru the transformer and measured 10 nF across that capacitor using Smart Tweezers at 10kHz.

On another OBC from Joe with the waffle plate and everything intact, then i was getting intermittent readings on those capacitors for both the 21-22 and 23-24 pairs of solder junctions. (e.g. zero to 4.5 to 6.5 pF readings)

If you try to measure those two capacitors in-circuit, then the resistance of the loop thru the transformer will overwhelm the reading, R ~250 Ohms shorts out the capacitance reading.

Good luck to you, hope the repair goes well.

[Ceregarak]

Привет всем ... мой OBC GEN 2 перестал заряжаться, выдал следующую ошибку P1D10 Output Current (Control Fail). Можете что-нибудь посоветовать?

[siggs]

OBC NEWS
My last successful OBC repair (4.7 ohm resistors + snubber) is documented in this thread.
Last posts on page 84. https://myimiev.com/forum/viewtopic.php ... &start=830
From Sa 18.12.2021, my I-MIEV 2011 was charged without any problems until last week.
Now 4.7 ohm resistor broken again (but looks like new)
Before I mounted the OBC cover after the last OBC repair, I checked the heating of the 4.7 ohm resistors
during the normal charging start. Temperature rise only approx. 3 K.
Newly identified problem, for the failure of the 4.7 ohm resistors, is the relay coil connection on relay RL1.
My currently defective OBC:
Measurement at the freewheeling diode D301, (with resistance range !) infinite resistance (normal approx. 59 ohms).
Lightly pressing the relay on the coil side, then suddenly 59 ohms. Bad solder joint.
The problem was discovered by the German "I-MIEV repair Pope" elektrozitrone from the forum:
https://www.goingelectric.de/forum
He's already fixed a few triplets with the same problem.
My current status:
Removed only upper circuit board. Defective relay surgically stripped. Save the PINs on the surface !
New parts coming this week. I will report with photos.
siggs
Slava Ukraini