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Part 2, finally edited and uploaded. hope this helps.. also, there could be other failure modes, that this might not fix. https://youtu.be/ynFKclou-LI Thank you to Kiev, Coulomb an Mikedufty for all your help, without you guys we wouldn't have taken on this repair. your expertise and...

finally put together a video of starting the repair of the converter. https://youtu.be/63ZWosSyq7Q

Merci, j'espère que votre solution va bien. Excuse my translation, I cannot speak French so used google.

Yes it is great, we are happy. Charged to 100% today and allowed to complete balancing. Then disconnected the 12V and drive battery, left it for a few hours and then filled the hole in the doghouse with neutral cure silicon. Now we have to wait 72 hours for it to fully cure, before I put the...

This morning we have put in the OEM fuse, and put it back on charge. Once we are at 100% SOC, we are going to disconnect the HV and 12V, open the OBC and repot the doghouse with neutral cure silicone.

And for the good news, it looks like ours is fixed, woot! So, what did we do. Replaced the two caps with new through the hole caps, however these were soldered to the pins with the two pins that were soldered onto the upriser board used for each leg of the caps (i.e. each leg had the two...

Alrighty, the resistors measured 9.7Ω, which I assume is correct (4.7Ω x 2 = 9.4Ω), so I assume that it good. Here is how I tested it. Full image: https://i.imgur.com/JdW1Kyh.jpg We are about to re-assemble the OBC, top up the coolant and run the coolant pump cycle, and see what happens. I...

Ok, relay is good, used bench top power supply set to 4.5V@500mA (@coulomb saw your post after I did the test), heard it click. Woot! Ok, so about to check the resistors.

I removed the riser board, had to cut it, I managed to save the pins, and soldered the new caps directly to the pins (2 pins per leg), and made sure they were secure. I am now testing the other components, about to test the semi's in the waffle board and the relay. When testing the relay...

@skylogger & @coulomb, thanks for the advice, we'll go with the JayCar heat transfer compound, and the natural cure silicone. We got the fuse from Mitsubishi yesterday, I have solar fuses and fuse holders shipping which we should have tomorrow which I will use initially for testing as I do not...

Hi All, Question regarding potting compound and heat transfer compound. Will the following work for our situation? Potting Compound: https://au.element14.com/robnor/el171c-566/resin-polyurethane-twin-pack-566g/dp/725973?st=potting https://au.rs-online.com/web/p/potting-compounds/0851044/...

Another one bites the dust. I just heard of another charger die in a Citreon C Zero by someone in the iMiEV Facebook group, I have advised the person to join this forum and post in this thread, hopefully he will soon. I chatted to him on Facebook, and he has exactly the same symptoms we have...

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...

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...

True, but I figured it would not be any worse that what was already there, and would make future repairs easier. I would definitely repot it if I put in a riser. I was thinking of designing and sending for a professionally produced PCB with screen printing, not something I etched myself.

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...

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...

Thanks @skylogger, I'll give it a go now.

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...

Thanks for the explanation @coulomb. Makes sense.