The Troubleshooting and Repair for On-board Charger (OBC) Thread

[Exhausted76]

See note added about the "blend"

Just to let you know. Full fix achieved and now charging. £4,000 saved by not giving it to the garage. Sincere and grateful thank you to YOU

 

[Daniel11]

Bonjour à tous
Ou achetez vous ces 2 résistances de 4,7 ohms en 7w et 10w
J'arrive pas à trouver les mêmes résistances
Merci

 

[kiev]

Bonjour

Hello everyone
Where do you buy these 2 resistors of 4.7 ohms in 7w and 10w
I can't find the same resistors
Thanks
=====
Howdy Daniel,
These are made in Japan by TAM and don't seem to be available thru normal electronics distributors.

i just use Mouser to find similar devices with same pin spacing and equal or greater power rating.

Easiest method may be to crush the remains and leave a bit of the internal leads with which to attach the replacement device (avoids need to remove the waffle plate™ 72 solder joints)

 

[Fuseit]

It might be possible to take the boards and cable components to an electronics repair shop (cell phones, tv, etc) to do the soldering?

How or why was the connector removed such as this--not sure i've ever seen this before.

Well tbh I believe the board had been worked on before I went in there as I was extremely careful and it still managed to separate. I did take the board to the phone repair shop and they couldn’t help as it was so fine. So I read online this professor of electronics mentioned you can use contact glue I went down to the store and purchased the clear gorilla contact adhesive and put a small blob on either end and pressed down for 10 seconds, it appears to of made contact with the board and the legs have also made a good contact. I’m waiting on my blue capacitors to solder in to replace the low spec ones that were put in by an electronics shop. I’ll update when everything is done and hopefully fingers crossed it will be ok. I don’t think by inspection of that ribbon connector it was ever soldered by the factory.

 

[kiev]

I don’t think by inspection of that ribbon connector it was ever soldered by the factory.

The factory uses solder paste which mainly connects on the bottom side with a tiny bit of solder, looks like nothing from the top but it's there.

But even if that might have been true in your case, then you still need to solder each pin to ensure good electrical continuity. If one of those connections were to bounce open while charging it could cause extreme damage to the waffle plate™ which is not an easy item to replace if you can even find one.

The trick is to use lots of flux, a fine tip iron slightly wetted with a bead of 63-37 or 60/40 tin/lead solder, and slowly drag the tip along the pins and pads. The solder from the bead will adhere to the pads and pins to make the joint. if excess is deposited or bridges form, they can be removed with a "dry" tip (i.e wiped clean with a wet sponge) which will draw solder from a joint, or by using copper wick made for desoldering, it comes in various widths #1-5 so get the thinnest #1 for this sort of work.

 

[Daniel11]

Bonjour à tous
Où acheter ces 2 résistances de 4,7 ohms en 7w et 10w
Je ne trouve pas les mêmes résistances
Merci
=====
Bonjour Daniel,
Ceux-ci sont fabriqués au Japon par TAM et ne semblent pas être disponibles auprès des distributeurs d'électronique habituels.

j'utilise simplement Mouser pour trouver des appareils similaires avec le même espacement des broches et une puissance nominale égale ou supérieure.

La méthode la plus simple consiste peut-être à écraser les restes et à laisser un peu de fils internes avec lesquels fixer l'appareil de remplacement (cela évite d'avoir à retirer les joints de soudure de la plaque gaufrée™ 72)

Merci à vous

 

[Eurotrash_87]

Hello everybody, I'm a new user here on the board and wanted to say hello to all of you amazingly smart individuals!

Now with that said I just bought a 2012 i-Miev from a local auction house for $375US. Its a bit basic with no CHAdeMO. Has 49k miles and seems to be in good condition overall. but since I'm typing this message inside the OBC thread I'm sure you know what I'm about to say....

So the car wont charge, through lurking and reading in this thread I found the MCU fuse was blown (hints as to way the 12v battery was dead) I inserted a jumper wire into the fuse holder and got 14.4v on the 12v battery. I even drove it about 5 miles and it drives well. Cool, now as for the OBC... the box is filled with black sooty stuff all over everything. the top board has been burned up but the bottom board (and caps) look ok although I haven't tested them with a multimeter yet.

I cleaned up the top board the best I can and will post before and after pictures.

 

[kiev]

Wow that is about the worst looking board blowout ever seen here.

The Line and Neutral have wide copper traces that cross over each other in the vicinity of the blowout. You can see the copper of the Neutral on top of the copper of the Line trace showing thru the hole. The traces are on top and bottom layers of the board and appear to have shorted thru the board to each other. Maybe a lightning strike ran thru the mains or a massive AC line over-voltage?

Since the fuse in the MCU blew then i suspect that there is some damage on the power board of the OBC also.

i doubt this much damage can be economically repaired; better to find a good used unit and get the car charging.

 

[Eurotrash_87]

Wow that is about the worst looking board blowout ever seen here.

The Line and Neutral have wide copper traces that cross over each other in the vicinity of the blowout. You can see the copper of the Neutral on top of the copper of the Line trace showing thru the hole. The traces are on top and bottom layers of the board and appear to have shorted thru the board to each other. Maybe a lightning strike ran thru the mains or a massive AC line over-voltage?

Since the fuse in the MCU blew then i suspect that there is some damage on the power board of the OBC also.

i doubt this much damage can be economically repaired; better to find a good used unit and get the car charging.

Thanks for the quick response Kiev, Yeah I knew It was bad when all the ones I see on the internet dont look anything like mine. The bottom board has no immediate signs of damage that I've noticed but I am not able to remove it from the housing. Im afraid of snapping the board with how hard I was prying on it. Well I guess Im in the market for an OBC :/

Here are some Photos I got from the lower Board... you can see someone was In there labeling wires with red marker. And black soot everywhere.