Enginer PHEV kit Rebuilt with quality components and new batteries

Thanks for the link.
I will check it out.

Jason.

 

Ahh.

Yes. Indeed. If that pack can be bought for 5K that would be interesting.
I fear it would be closer to 8k here in oz.

We get zero govt rebates or other incentives to buy and drive clean cars.
When the leaf launched here, they were 60K.

The volt still is 60k.
Crazy numbers. Even at 40k the leaf is still over priced for what it is.

Jason.

 

I got a reply from Eric. $950AU shipped at current exchange rates.

Thanks again for the link.

Jason.

 

So today I found someone at my local electronics store (Jaycar) that was willing to have a look inside the converter to see if it might be an easy fix.

He's a freshly graduated electrical engineering dude.
Seems keen to at least have a look for me. Who knows. Might even be able to save me some money.

Does anyone have any info / pics on the insides of the converter ?
Anyone here ever posted pics of a tear down ?

Any info that I can find might be useful.

Jason.

 

Thanks for the info. I'll keep looking for those pics.

My converter already has 2 extra fans mounted above the case.
They are hooked to the same fan that is inside the converter.
So as soon as that one comes on, the two external ones also roar into life.

It's a bit noisy, but I can live with it.

I have had a chance to have a closer look over the system, and It looks like the main 100A breaker tripped. If that's the case, I'm guessing it's an internal short inside the converter somewhere.
I havnt been keen to try resetting it, just in case it makes the problem worse.
If it has tripped, there is a reason that it did.

Most likely an output FET.
So hopefully it shouldn't be that hard to find and replace.

I now have 2 options open for possible repair.

The guy I met at the electronics store,
And I had someone send me a link to a professional repair place that specializes in chargers and inverters and the like.

So if the first option doesn't find anything,
I'll send the pros an email and see if they can help.

I'll have more info in about 2 weeks.
Can't do anything till then, I'm busy next weekend.
I have a 85km charity bicycle ride planned.

Again,
I'll keep this thread updated.

Jason.

 

so....

the first option didn't work out, and i had help today to remove the converter from the car.
im taking it to the repair shop Monday morning.

while it was out of the car, i took the opportunity to open the lid and have a quick look inside.
my untrained eyes couldn't see anything obviously melted / blown up.
& nothing discolored or obviously out of place...

i also tested all 4 of the fuses near the input to the converter.
all 4 are ok, so it's not the fuses....

i have taken a few pics for those that might be interested.









i will report back if the shop is able top repair it or not.and how much it costs to fix....

Jason.

 

That was my thoughts

One or more of the fets are likely blown or shorted.

I'm dropping the converter off for a potential repair quote tomorrow
Testing the fets is beyond my capabilities.

I'll post what happens next.

On a related note, I filled up tonight after having the system not running and only managed 4.18L per 100km and 870km.
Not the greatest.

Jason.

 

Yep. That's very true.

Still I got so used to being at about half that.
Hopefully I get some good news soon.

Jason.

 

Update:

Got the converter back from the repair place today.
They opened it up, inspected inside, ran some tests and were able to get it running on the test bench.
However, they didn't actually replace any components.

So they think the problem is elsewhere in my system.
I'll try to re install the converter this weekend and see if it works or not, and if not, I guess I have more trouble shooting to do.

Does anyone know if the front mounted switch is prone to failures ?
Mine appears to still work, the green led still lights up when the switch is on.

Wondering now if that switch could fail and that might be the reason it's not turning the converter on ?
Even though the green led comes on.

As always, I'll keep this thread updated.

Jason.

 

Thanks for the diagram. I'm sure it will prove very helpful.

I'm not sure if the workshop tested the converter under load or not.
I wasn't there at the time.

But as you say that if the green light is on, then the converter should be working.
See what I can figure out this weekend.

Thanks again.
Jason.