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by kiev
Tue Jul 24, 2018 6:24 am
Forum: Modifications & Accessories
Topic: Supplemental cooling for the charger.
Replies: 74
Views: 50145

Re: Supplemental cooling for the charger.

A web search came back with a story that nichicon agreed to pay $42M to settle a USA Dept of Justice case that accused them of price fixing electrolytic capacitors. Later reports indicated that many more companies were included in this lawsuit. So it may be that there is not much e-cap support in th...
by kiev
Tue Jul 24, 2018 5:55 am
Forum: Batteries and Battery Management
Topic: Troubleshooting and repair for On-board Charger (OBC)
Replies: 748
Views: 461562

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

@coulomb, i used an xacto knife to scrape the epoxy off the diode. It is a very brittle material, and in a thin layer it can be levered off with a blade. Also i use a hot solder iron on thicker sections--the heat pulverizes the surface to a gray powdery dust. So heat and scrape, rinse and repeat unt...
by kiev
Mon Jul 23, 2018 9:37 pm
Forum: Batteries and Battery Management
Topic: Troubleshooting and repair for On-board Charger (OBC)
Replies: 748
Views: 461562

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

Hi Kiev: On your schematic of the Doghouse, you show the output of the drawing which will either be from the closed relay, or from the bypass resistors. If the pcb is still fitted in the box and heatsink still intact, so you cannot probe the bottom of the board, is there any points on top of the bo...
by kiev
Mon Jul 23, 2018 7:17 pm
Forum: General Technical Discussions
Topic: Charge problem?
Replies: 3
Views: 3628

Re: Charge problem?

Get a flashlight and look down into the charge port sockets to see if there is any debris, moisture or insects. A cotton swab dipped in alcohol can be used to clean them out. i had fireants build a nest in my evse handle and over time the crushed ant debris was shorting out the terminals in the port...
by kiev
Sun Jul 22, 2018 5:59 pm
Forum: Batteries and Battery Management
Topic: Troubleshooting and repair for On-board Charger (OBC)
Replies: 748
Views: 461562

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

... A few questions: 1. What are the length and diameter in mm of these caps? From your photo I make it to be about 35mm dia. 2. I take it these are part of the output LC filtering and experience full pack voltage? 3. I don't understand their four-terminal configuration. Schematic? Howdy Joe, 1. Lo...
by kiev
Sun Jul 22, 2018 2:19 pm
Forum: Batteries and Battery Management
Topic: Troubleshooting and repair for On-board Charger (OBC)
Replies: 748
Views: 461562

Swollen Capacitors, plus a precharge simulation

2 of the 3 big nichicon 420V 680uF capacitors in jay's box have bowed up the top dome of the relief valve/notch. i don't have a reference designator for them, so for now they are 1,2,3 from left to right, where number 3 is closest to the big hot inductor during charging. https://i.imgur.com/kPrnDma....
by kiev
Sun Jul 22, 2018 1:29 pm
Forum: Modifications & Accessories
Topic: Supplemental cooling for the charger.
Replies: 74
Views: 50145

nichicon Charger and DC/DC Converter

The box has a nichicon part number, and looking thru their website i found they take credit for the miev OBC. In fact they claim that it worked so well for Mitsubishi that Nissan converted over to using their design in the Leaf. Here is a page from a product brochure: https://i.imgur.com/YDuVwwf.png...
by kiev
Sun Jul 22, 2018 12:46 pm
Forum: General / Main Owners Forum
Topic: And now my I will not charge!!
Replies: 45
Views: 30955

Re: And now my I will not charge!!

i posted the schematic in the troubleshooting thread. The two big 4.7 Ohm ceramic resistors are connected in series and provide a bypass path across the relay contacts. These are made by Tamura, the larger one with green ink (TAM P10K series) is a thin-film current-limiting fuse, and the smaller one...
by kiev
Sun Jul 22, 2018 6:36 am
Forum: Batteries and Battery Management
Topic: Troubleshooting and repair for On-board Charger (OBC)
Replies: 748
Views: 461562

PA4080RP100 Board, AC Input Filter and Relay

Jay's charger box has this nichicon part number on the bottom board, so we can use this as a reference designation as needed. Here is the trace for most of the stuff in the bottom board potted region, aka the AC Input doghouse. The two big 4.7R ceramic resistors are connected in series and provide a...
by kiev
Sat Jul 21, 2018 9:53 pm
Forum: Modifications & Accessories
Topic: Supplemental cooling for the charger.
Replies: 74
Views: 50145

Re: Supplemental cooling for the charger.

... kiev, did you leave the cover in place and then remove it to make your measurements, or was the cover off the whole time? What's troubling with kiev's measurements is the high temperatures achieved by the magnetics. Even if they used hi-temp insulation, the heat generated and dissipated within ...

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