coulomb
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Location: Brisbane, Australia

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

Mucker wrote: Fri Jul 08, 2022 12:06 pm I hope this time the drive document is working.
Works for me.
I desoldered the waffleplate once again and measured with the LCR T4 Mega components tester the like I draw in here.

https://drive.google.com/file/d/1RyrtwH ... sp=sharing
The 0,07 Ω across the IGBTs is very bad. I assume that short comes from the Waffle Plate™. If so, it means that your IGBTs are shorted. I can only recall one very minor repair of a waffle board; they are very hard to deal with, and we don't know the correct replacement parts. Likely and DPAK 600+V 50A+ IGBT would do, but it's not known. Gate driver components on the PCB may also be damaged.
kiev
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Re: Troubleshooting and repair for On-board Charger (OBC)

Yes the google documents show up now, you did a good job measuring the waffle plate values in the second document; unfortunately it is badly damaged as coulomb mentioned.

It cannot be repaired but the entire waffle plate could be swapped out from another OBC after checking all the diode drops first to verify it is not damaged. The 2011-2012 nissan laefs also use this exact same plate in their OBC, so that opens up a wider source for a replacement.
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shuma89
Posts: 13
Joined: Mon Nov 15, 2021 4:47 am

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

I am beginer.
i want to know wich type of IGBT swiching control is used to control WAFFLE PLATE IGBT-s? 8 IGBT for inverter and 3 IGBT for power conditioning.
kiev
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Re: Troubleshooting and repair for On-board Charger (OBC)

The 3 IGBTs used in the power conditioning section are driven by signals from an IC located on the power board. This ic performs a PFC function, that is Power Factor Control, which is the alignment of the voltage and current to be in-phase, by the switching action of the transistors of the Boost converter.

The 8 IGBTs of the inverter section are just 2 H-bridges using PWM, Pulse Width Modulation switching to create an alternating current thru the windings of the step-up transformers to control the voltage and current of the OBC output to the pack.
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shuma89
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Joined: Mon Nov 15, 2021 4:47 am

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

kiev wrote: Wed Jul 20, 2022 12:13 pm The 3 IGBTs used in the power conditioning section are driven by signals from an IC located on the power board. This ic performs a PFC function, that is Power Factor Control, which is the alignment of the voltage and current to be in-phase, by the switching action of the transistors of the Boost converter.

You can point on the power board this IC?
kiev wrote: Wed Jul 20, 2022 12:13 pm
The 8 IGBTs of the inverter section are just 2 H-bridges using PWM, Pulse Width Modulation switching to create an alternating current thru the windings of the step-up transformers to control the voltage and current of the OBC output to the pack.

and what controlls the PWM for IGBT-s of inverter?
kiev
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Re: Troubleshooting and repair for On-board Charger (OBC)

The PFC chip is IC312, located on the bottom side of the power board, UC2845. There is a picture of this in the first post on page 1.

The microcontroller on the upper control board sends the signal for the H-bridges.

Are you trying to make a repair?
Last edited by kiev on Sat Jul 23, 2022 8:22 am, edited 1 time in total.
kiev = kenny's innovative electric vehicle
nnasskoo
Posts: 1
Joined: Sat Jul 23, 2022 1:31 am

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

Hi, I have a broken charger with error Code No. 17: Inside Ambient Temperature Abnormal (boost circuit rectifier temperature abnormal) which is permanent. Any idea where this sensor is located?In hybrid fet boart?
kiev
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Re: Troubleshooting and repair for On-board Charger (OBC)

Howdy nnasskoo and welcome,

i think it is in the hybrid fet board, aka waffle plate, on the pair of solder junctions labelled 17 and 18 in the silkscreen of the power board. Located on the right column, third row from the bottom.

My notes show it measured 90k resistance, i didn't try heating or cooling to see how that changes but could if needed.
kiev = kenny's innovative electric vehicle
Foreb
Posts: 1
Joined: Sun Aug 14, 2022 1:47 pm

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

Greetings. I have broken charger. DC-DC works, charging does not. I am getting these error codes from my OBC:

15 Power factor correction (PFC) circuit temperature abnormal
16 Temperature in increasing voltage area abnormal
17 Inside ambient temperature abnormal (boost circuit rectifier temperature)
31 Temperature in increasing voltage area abnormal 2

Car does not even start to charge, but I am getting all these errors. Hard to believe that all is overheated without charging.
Any idea where this sensors are located ? What could I try or look for ? Maybe some fuse, which is responsible for all these sensors.
Virusman
Posts: 10
Joined: Wed Jan 29, 2020 1:21 pm

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

Hi guys, I have on my desk a broken charger. Cups and resistors are ok, I replace them before.
My question is, is it possible to connect ac power line to charger and measure voltages? I don't have car, I just looking some tests to he sure that charger can work.

Second questoon: p1a12 any solution for this error?

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