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by electronpusher
Sun Sep 23, 2018 3:18 am
Forum: Batteries and Battery Management
Topic: Troubleshooting and repair for On-board Charger (OBC), DC-DC Converter
Replies: 225
Views: 8308

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

Thanks @skylogger for the info. I was hoping to save the riser, but I should be able to take the measurements I want off it first, before cutting it up for removal. Finished up for the night, but tomorrow night I'll give it a go, and also check the semi's on the waffle and relay. Still waiting on th...
by electronpusher
Sat Sep 22, 2018 11:40 pm
Forum: Batteries and Battery Management
Topic: Troubleshooting and repair for On-board Charger (OBC), DC-DC Converter
Replies: 225
Views: 8308

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

Ok, removed the potting around the riser, and had a go with some solder wick to remove the riser board, without success. I think the waffle has to come off. Thoughts? Any suggestions on how to remove the riser without removing the waffle? If the waffle has to come off, I will take it to uni where I ...
by electronpusher
Sat Sep 22, 2018 11:31 pm
Forum: Batteries and Battery Management
Topic: Troubleshooting and repair for On-board Charger (OBC), DC-DC Converter
Replies: 225
Views: 8308

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

I think you'd want to re-pot the (new) vertical PCB, so I don't see much advantage unless the capacitors were up high out of the main potting. The extra lead length might introduce too much inductance. Though the existing PCB would have nearly as much inductance. Perhaps really thick tracks, perhap...
by electronpusher
Sat Sep 22, 2018 10:50 pm
Forum: Batteries and Battery Management
Topic: Troubleshooting and repair for On-board Charger (OBC), DC-DC Converter
Replies: 225
Views: 8308

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

Additionally, I had a look at the riser board, there is no way to mount the caps on there, however I was thinking of designing a new riser board that will accept through the hole caps, thus making future repairs easier. Basically you would remove the potting once, replace the riser or through the ho...
by electronpusher
Sat Sep 22, 2018 10:45 pm
Forum: Batteries and Battery Management
Topic: Troubleshooting and repair for On-board Charger (OBC), DC-DC Converter
Replies: 225
Views: 8308

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

Once I removed those spacers, the board came out really easy. Did not appear to be much heat transfer compound on the bottom of the waffle plate. Any recommendations for replacement paste, or will any old heat transfer compound to? So now I am going to be removing the black potting from around the r...
by electronpusher
Sat Sep 22, 2018 9:43 pm
Forum: Batteries and Battery Management
Topic: Troubleshooting and repair for On-board Charger (OBC), DC-DC Converter
Replies: 225
Views: 8308

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

Hi All Open heart surgery on our iMiEV has begun. I have opened up the OBC, removed the top board, and removed all the screws that I know of that hold the middle board (with the blown caps) from the OBC, but it will not budge (with light force), and I am too afraid to apply too much force, because I...
by electronpusher
Thu Sep 20, 2018 9:37 pm
Forum: Batteries and Battery Management
Topic: Troubleshooting and repair for On-board Charger (OBC), DC-DC Converter
Replies: 225
Views: 8308

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

So with these non OEM fuses, does anyone think it would be doable to convert the fuses without screw terminals into fuses with screw terminals by soldering the fuse to some copper fashioned into screw terminals and soldering the fuse to the copper?
by electronpusher
Thu Sep 20, 2018 9:27 pm
Forum: Batteries and Battery Management
Topic: Troubleshooting and repair for On-board Charger (OBC), DC-DC Converter
Replies: 225
Views: 8308

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

Electronpusher: When I ran into problems getting the original 20 amp fuse, I bought the 10x38 fuse type that you showed in your last post. To be able to use it, I also bought a DIN fuse holder, and ran wires from the fuse holder with small ring terminals that would screw down to the original two sc...

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