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Some brave testing and swapping has pushed the envelope of knowledge, bravo! Those are great pictures to show some details and differences between the red-coated boards and the clear-coats, aka green boards. The flex spring conducting wires of the clear coats replaced the flexible circuit...

and post #119 is good too. That OBC has the cover of the Gen 2 units, but inside it is still Gen 1 with the single waffle plate. Some of the early 2009-2010 models used a Gen 0 which had several mini waffle pads. It would be an interesting test if someone with a Gen 1 or 2 OBC that normally...

It appears that you have an intermittent fault related to CMU 9, as it was faulting in original location, then with a module swap; and then no fault when the location was swapped. That hasn't solved anything or gotten to a root cause. Inspect the daisy chain wiring for damage and connector...

That looks to be a Gen 2 OBC unit. do you have a question about it?

That's a 20A fuse in the HV DC Output Section. Never reported to have failed, even when the snubber caps and the MCU fuse fails.

L and N refer to Line and Neutral of the incoming AC (for 120vac). With 240vac both sides are "hot" but the OBC doesn't care and it will charge faster and higher power. The resistance measurement is with no power, but just uses the meter to check the continuity/resistance thru the board to the...

Need to see the DTCs to know. The scorch marks don't mean it is broken, they just run hot and the cheap plastic tubing outgasses and the vapors condense on the cooler lid. The blue snubber caps appear intact so likely the car will still go to READY and the 12V battery is getting 14.4 ? i.e...

Did you mean to swap the cells to another location but leave the CMU board in the same "slot" location? It was my understanding that due to the daisy chain link, the CMU numbering is tied to a fixed location (slot or tray) molded into the pack, and this number is stored in the eeprom on the...

Post up a picture or two of the inside of your OBC--we might be able to give better advice seeing which version, extent of damage, etc.

Take a look at this list of links to troubleshooting and repair threads: https://myimiev.com/threads/my-t-r-list.5617/#post-49698

Here and other places too, troubleshooting and repair threads listing mymiev forum, as kiev dcdc Converter https://myimiev.com/threads/gen1-dcdc-converter-troubleshooting-and-repair.4737/ On Board Charger OBC...

Excellent video. Great instructions especially showing how the connectors get released. The output of an OBC is just a HV DC that gets routed directly to the main pack + and - thru the main contactors inside the pack. There is no direct connection between any CMU boards and the OBC. CMUs...

re 1. Yes a verified good and strong 12V battery is necessary to rule it out as the issue. A failure or drop-out of the 12V power could be the root cause for the blown snubber capacitors on that little daughter board with all the charring. The good side is that you can just carefully remove...

ELM 327 is a chipset used by some OBDII dongles for negotiation of the Hayes AT Modem commands used to communicate with the vehicle. The OBDLink uses an STM chipset which is a better solution. There are lots of counterfeits out there and elm devices which don't work, so beware.

Or the charging cable with no EVSE controller has been damaged and no longer works. As i understand it that cable has embedded resistors in the handle and plug to measure temperature and provide for the protocol handshake, etc.

There is no CAN buss to the DCDC Converter--it is controlled with discrete voltages from the EV-ECU. All DTCs are stored and reported by the EV-ECU. There is a separate thread with schematics and info for troubleshooting the OBC.

Did you use penetrating fluid? Carefully read the first post again. Brute force not recommended, it is a plastic housing. BTW you have absolutely not followed the directions or order of removal at all. No need to remove the cotter pin and cable to get the SPS off; also don't remove the...

Check the ceramic resistors: https://myimiev.com/threads/swapping-obcs-as-diagnostic-safe.5606/post-49462 Don't know about the coolant, but swapping OBC sounds like a good idea.

That is a very interesting lift that you were using--is it a custom built or is it a commercial brand? And the feature with the separate rails--what is that called and how does it work? It looks to be ideal for a battery swap.

Amazing video, thank you so much for taking the time to do this and for sharing it here.