[ The P1A15 Troubleshooting Thread ] No READY. P1A15 error. Condenser charge timeout.

[vik013]

I bought a MCU at a junkyard ($230). I'll be able to study the issue in more detail in a few days.

 

[vik013]

I think there is another reason for this error (not the hybrid board). I installed my MCU in another car and it works there. I installed it back and it works. And I didn't even have to reset the error with a scanner, the car turned on right away. I noticed that in the post above (in Austria), as in my case, work was recently done on the battery pack.

 

[Jakob N]

[Mod Edit: removed incorrect board layouts]

I made two boards for mounting the AD202KY
One mounts horizontally to the existing holes on the main PCB, the other one is mounted vertically, and will need so glue for preventing damage due to vibrations.
As my inverter is already running in the car again I can not test it now, but maybe someone will find this usefull in the future.
PCBs were drawn in eagle (Fusion electronics) If needed I can export the Gerber- files.

On the vertical version 90 degree angled pinheaders need to be used;
Alternatively standard- pinheaders can be soldered to the board like SMD- parts.



On the horizontal PCB special care needs to be taken that the pins of the AD202 don't cause a short- circuit on the Main PCB, as the replacement board is bigger than the original ISA- board!



As I have not tested the boards the manufacturing and usage of these boards is done on ones own responisbility!
Only attempt this repair if you know what you are doing!

BR

 

[Johannes Pedersen]

Jakob N

Nice job you have done.
Do you have some horizontal PCB for sale ?
I live in Denmark and I have two C-Zero with not working ISA PCB. My son is electrican and he can replace the PCB for me.
I think I will order two AD202KY tomorrow.

 

[Jakob N]

Hi Johannes,
I don't have them for sale, but you can order from JLCPCB. They offer PCBs at a great price for such projects.
You will need the Gerberfiles to order from them; I can create them for you if you are not familiar with PCB design software.
BR

 

[dezito]

I made two boards for mounting the AD202KY
One mounts horizontally to the existing holes on the main PCB, the other one is mounted vertically, and will need so glue for preventing damage due to vibrations.
As my inverter is already running in the car again I can not test it now, but maybe someone will find this usefull in the future.
PCBs were drawn in eagle (Fusion electronics) If needed I can export the Gerber- files.

On the vertical version 90 degree angled pinheaders need to be used;
Alternatively standard- pinheaders can be soldered to the board like SMD- parts.

View attachment 1554

On the horizontal PCB special care needs to be taken that the pins of the AD202 don't cause a short- circuit on the Main PCB, as the replacement board is bigger than the original ISA- board!

View attachment 1553

As I have not tested the boards the manufacturing and usage of these boards is done on ones own responisbility!
Only attempt this repair if you know what you are doing!

BR

Isn't there an error in this pcb with pin 38 (OUTPUT HI) and pin 37 (OUTPUT LOW), i have mounted the psb with ad202ky and it didnt work, but i found out the 12v battery was low, so im waiting to try again when its fully charged

 

[kiev]

Isn't there an error in this pcb with pin 38 (OUTPUT HI) and pin 37 (OUTPUT LOW),

Good catch to find that error, Yes there is an error, don't use that board layout.

 

[dezito]

Yes there is an error, don't use that board layout.

already did, can u see if this is correct

 

[kiev]

can u see if this is correct

Yes that is correct.

i have removed his layout diagram so hopefully nobody else gets damaged.

 

[dezito]

It worked with the modification to pin 37 and 38

 

[dezito]

Well driving works now, but i cant ac charge it now, i get P1B08 & P1A12, it starts up charging for about 30 sec and the ! flashes and then the red charging plug starts blinking, i also notes that when i drive and it start to regen it some times briefly stops regen and then kicks in again.

I used AD202KY (Made by ATI), because i couldnt get the one from Analog Devices Inc

I fully charged the 12v battery

All the cells is between 4.005-4.015v

 

[MickeyS70]

Well driving works now, but i cant ac charge it now, i get P1B08 & P1A12, it starts up charging for about 30 sec and the ! flashes and then the red charging plug starts blinking, i also notes that when i drive and it start to regen it some times briefly stops regen and then kicks in again

P1B08 seems to suggest that the smoothing capacitor’s voltage inside the inverter (MCU) is too high (>380V)
http://mmc-manuals.ru/manuals/i-miev/online/Service_Manual/2017/54/html/M154921560008801ENG.HTM

Looks like the OBC is causing this, as otherwise, you would have the same issue while driving.

P1A12 is a generic OBC error
http://mmc-manuals.ru/manuals/i-miev/online/Service_Manual/2012/54/html/M154950060003800ENG.HTM

You will need a diagnostic tool (MUT3/Diagbox etc) to determine the exact error code but error 01 (abnormal output voltage) seems plausible given P1B08 is happening at the same time..

Have a look here for OBC issues:
https://myimiev.com/threads/the-troubleshooting-and-repair-for-on-board-charger-obc-thread.4079/

 

[kiev]

I used AD202KY (Made by ATI)

That is an unknown entity for me. Sorry to hear that it may be causing charging issue.

Do they have their own datasheet with specifications for performance, error, linearity, etc?

Did you happen to test it on the workbench and compare the output for a given input?

My thoughts are that it might have higher gain thru the amplifier stage such that it is sending a higher output voltage to the controller, causing the fault and DTC.

i somewhat remember posting in this thread to someone that they may need to add a 2k resistor on the input, seems like that was found in the Analog Devices datasheet, but i will have to research this again.

 

[dezito]

here is the datasheet for both
AD202KY: https://www.mouser.dk/datasheet/2/609/AD202_204-3118475.pdf
AD202KY from ATI: https://www.analogtechnologies.com/document/AD202KY_(Made_by_ATI).pdf

 

[MickeyS70]

That is an unknown entity for me. Sorry to hear that it may be causing charging issue.

Well spotted, an alternative would have been AD202KNATI as (according to the manufacturer) it’s an ‘upgraded drop in replacement’ for the ‘tried and tested’ AD202KN.

https://myimiev.com/threads/the-p1a...5-error-condenser-charge-timeout.4225/page-28

https://www.analogtechnologies.com/document/AD202KNATI.pdf

Going back to post #563, it appears that AD202KY was never actually tested in a triplet although the only difference seems to be the packaging?

 

[dezito]

As I remember when I pulled the board out and tried to repair it, the battery was around 30%, but when I first tried to repair it, with the bad designed PCB with pin 37 & 38 swapped, it jumped to 60%, so I am thinking it maybe at battery percentage calculation error and maybe try to discharge it as much as I can and try to charge it again.

I can also on Monday, drive to my auto mechanic, to read the error under P1A12

 

[MickeyS70]

, so I am thinking it maybe at battery percentage calculation error

You can force a voltage based SoC calculation by disconnecting the 12V aux for a few minutes…

 

[dezito]

ok ill try that

 

[kiev]

Thank you for the datasheets, i will review this morning.

i wonder if it is an old code from when the pins 37 and 38 were crossed, and maybe just clearing of the codes would work.
=====

There is a basic difference between the AD and ATI device--the internal grounding of pins 32 and 37. i measured several Meg Ohms of isolation on one of the AD202 here on my bench. The ATI datasheet shows that 32 and 37 are internally connected.

The 2k resistor on the input to pin 1 is discussed in the AD datasheet as needed to prevent inadvertent currents when the device is off due to negative voltage condition--probably not a concern or likely to happen for us.

i don't know what would happen on the MCU control board with 32, 37 and 38 all connected together on both the ground and the output of the "hybrid".

It makes me wonder if the Regen glitch is related to this also, in that the "sensed" HV at the capacitor appears to exceed the traction pack voltage, i.e. It is not a real thing but due to instrumentation error.

i don't know what all is involved with international mailing, but i could send you a real AD version if you determine an issue with your ATI.

 

[dezito]

I have cleared all the codes and my auto mechanic also cleared the ones I couldn't