[kennybobby]

So you have a 6.6kW charger?

If i understand the story, the charger has been working fine for several months, then it quit?

Do you know or think that the U100A only showed up after the OBC quit working?

Seems odd that a CAN buss message could be missing and it would work, then suddenly not work.

A hardware fault could cause a message issue, but which message...? And which hardware?

Since you have it open might as well check the diode drops of the HV rectifiers that feed the transformers, and the switching fets of the H-bridges, there are freewheeling diodes in the fets/igbts. Same for the fets on the PFC section, check for diode drops and look for shorts.

 

[evVanagon]

So you have a 6.6kW charger?

Yes

If i understand the story, the charger has been working fine for several months, then it quit?

Yes it's was working great. Just no QC charging (see separate thread). That's what i was troubleshooting while L1 charging was working and i was able to get back and forth to QC stations. Now I can't since November because it won't charge.

Do you know or think that the U100A only showed up after the OBC quit working?

No, i've always seen the U100A message popup, especially with QC charging and generally every time the IGN goes ON. Being able to see the U100A message is realtively new to some of us because the LeafSpy app never showed the "Charger" ECU's DTCs. Turbo added it to the app in October 2022.

Seems odd that a CAN buss message could be missing and it would work, then suddenly not work.

Yeah very odd. Im not to sure that the U100A is causing no charging.

A hardware fault could cause a message issue, but which message...? And which hardware?

This is what I was checking with having injected theose CAN messages into the system. Removing each message one by one didn't give a solid answer to which message was missing. Also just by cross comparing darko's successfull charging can log to one of my logs, all messages are present.

Since you have it open might as well check the diode drops of the HV rectifiers that feed the transformers, and the switching fets of the H-bridges, there are freewheeling diodes in the fets/igbts. Same for the fets on the PFC section, check for diode drops and look for shorts.

Yup, checking everything. Thanks for this info. I'm new to power electronics. Second time i've opened this now and going to test each component.


Here's more pictures as I slowly dissasemble.

What i've found so far

• The four inductors (black cylinders, two by the input and two on the output) are all closed circuits.
• Open circuit across the transformers (in the direct middle, pink and blue). Closed circuit from blue to blue on one transformer and Closed circuit on pink to pink on the other transformer.
• D102 (near the input bus bars, third picture) - tests good.
• 150k Ohms across DC +/- ouput. (far left of picture one next to choke).

 

[kennybobby]

Nice pictures, thanks for posting.

 

[evVanagon]

Update: still nothing yet.

• These diodes, D2001-D2008 all have 22ohms forward and backwards and 0.010V forwards and backwards. This seems odd.
• Leads are positive to the right then leads swapped for other value.
  • D2031 = 0.117V one wya and 0.961V other
  • D2032 = 0L one way and 0.117V other
  • D2033 = 0.117 and 0L
  • D2034 = 0.890V and 0.117V
  • 
    
  • D2042 = 0.117V one way and 0.965V other
  • D2041 = 0L one way and 0.117V other
  • D2043 = 0.117V and 0L
  • D2044 = 0.905V and 0.117V
  • 
    
  • D522 = 0.117V and 0.964V
  • D521 = 0L and 0.119V
  • D523 = 0.116V and 0L
  • D524 = 0.903V and 0.117V
  • 
    
  • D532 = 0.117V and 0.964V
  • D531 = 0L and 0.119V
  • D533 = 0.117V and 0L
  • D534 = 0.912V and 0.117V
• These transistors (3 terminal, underneath this board, maybe connected to TP2182-TP2189).

- TP2186 (near outside edge of PDM)​

- B+ to E- = 0.990V - 8.32 kOhms​

- B+ to C- = 0L = 3.67 MOhms​

- C+ to E- = 0L = open​

- C+ to B- = 0L - open​

- E+ to B- = 0.137V - 717 Ohms​

- E+ to C- = 0.370V - 3.66 MOhms​

- TP2187​

- B+ to E- = 0.952V - 4.57 kOhms​

- B+ to C- = 0L = 2.72 MOhms​

- C+ to E- = 0L - open​

- C+ to B- = 0L - open​

- E+ to B- = 0.133V - 693 Ohms​

- E+ to C- = 0.368V - 2.72 MOhms​

- TP2188​

- B+ to E- = 0.990V - 8.14 kOhms​

- B+ to C- = 0L = 3.62 MOhms​

- C+ to E- = 0L - open​

- C+ to B- = 0L - open​

- E+ to B- = 0.135V - 703 Ohms​

- E+ to C- = 0.369V - 3.65 MOhms​

- TP2189​

- B+ to E- = 0.954V - 4.49 kOhms​

- B+ to C- = 0L = 2.72 MOhms​

- C+ to E- = 0L - open​

- C+ to B- = 0L - open​

- E+ to B- = 0.135V - 696 Ohms​

- E+ to C- = 0.370V - 2.76 MOhms​

- TP2182 (near middle of board)​

- B+ to E- = 0.989V - 8.14 kOhms​

- B+ to C- = 0L = 3.54 MOhms​

- C+ to E- = 0L = open​

- C+ to B- = 0L - open​

- E+ to B- = 0.135V - 701 Ohms​

- E+ to C- = 0.369V - 3.55 MOhms​

- TP2183​

- B+ to E- = 0.961V - 4.43 kOhms​

- B+ to C- = 0L = 2.67 MOhms​

- C+ to E- = 0L - open​

- C+ to B- = 0L - open​

- E+ to B- = 0.135V - 696 Ohms​

- E+ to C- = 0.368V - 2.66 MOhms​

- TP2184​

- B+ to E- = 0.988V - 8.06 kOhms​

- B+ to C- = 0L = 3.61 MOhms​

- C+ to E- = 0L - open​

- C+ to B- = 0L - open​

- E+ to B- = 0.134V - 692 Ohms​

- E+ to C- = 0.370V - 3.62 MOhms​

- TP2185 (near transformers)​

- B+ to E- = 0.954V - 4.25 kOhms​

- B+ to C- = 0L = 2.56 MOhms​

- C+ to E- = 0L - open​

- C+ to B- = 0L - open​

- E+ to B- = 0.133V - 685 Ohms​

- E+ to C- = 0.368V - 2.57 MOhms​

​

• These 8x output rectifying diodes test well. Hidden underneath this board. 0.336V forward for each. 0L reverse
• R705 = L1 to E11 = 215 kOhms
• C705 = not open, parrallel to R705
• C704 = not open, parrallel to R705
• C703 = not open, parrallel to R705
• Output capacitor - Next to E2016 = open
• C701 = 15.03 MOhms
• C762 - 0L
• 
  
• R2001 = L1 to E2004 = 215 kOhms
• C202 = not open, parrallel to R2001
• C203 = not open, parrallel to R2001
• C204 = not open, parrallel to R2001
• Output capacitor - Next to E2013 = open
• C2001 = 15.25 MOhms
• C2025 - 0L
• 
  
• C713 = 337 kOhms, which is equivalent to across R706 to R707 to R708 in series at 260 kOhms each (doesn't make sense here, should 750 kOhms ish)

- These two transformers(?) have continuity as well. One in picture and the other on otherside of PDM. Both identical shapes.

Next, otherside of the black capacitors that seem to have components of 1 diode and 2 transistors on each side.
- Side 1: (same side as C2017 and C2016)

- Diode (near outside edge of PDM)​

- 0.353V forward and 0L reverse​

- Transistor #1 (closest to diode)​

- B+ to E- = 0.847V - 5.04 kOhms​

- B+ to C- = 0.961V = 2.65 MOhms​

- C+ to E- = 0L - open​

- C+ to B- = 0L - open​

- E+ to B- = 0.539V - 5.04 kOhms​

- E+ to C- = 0.350V - 2.92 MOhms​

- Transistor #2 (in front of R3022)​

- B+ to E- = 0.842V - 4.82 kOhms​

- B+ to C- = 0.955V = 2.93 MOhms​

- C+ to E- = 0L - open​

- C+ to B- = 0L - open​

- E+ to B- = 0.171V - 1.81 kOhms​

- E+ to C- = 0.349V - 2.91 MOhms​

​

- Side 2: (same side as C113 and C112)

- Diode (neare transformer)​

- 0.372V forward and 0L reverse​

- Transistor #1 (closest to diode)​

- B+ to E- = 0.838V - 4.16 kOhms​

- B+ to C- = 0.951V = 2.94 MOhms​

- C+ to E- = 0L - open​

- C+ to B- = 0L - open​

- E+ to B- = 0.159V - 727 Ohms​

- E+ to C- = 0.370V - 3.62 MOhms​

- Transistor #2 (in front of R3023)​

- B+ to E- = 0.835V - 4.01 kOhms​

- B+ to C- = 0.949V = 2.94 MOhms​

- C+ to E- = 0L - open​

- C+ to B- = 0L - open​

- E+ to B- = 0.157V - 729 Ohms​

- E+ to C- = 0.349V - 2.93 MOhms​

​

R3010 and R3016 = continuity, seems odd.
R583 and the equivalent across from it are both = 177.9 kOhms
R581 - can't measure it.

R3022 = open
R3023 = 10.14 kOhms

Transformers (small, not sure how to test these, 5 terminals each side)
MT003 - S42C
So110 S41E

​

 

[evVanagon]

Top board: (Left side positive first)
D102 = 0.375V and 0L = 2.9 Mohms and 0L
D101 = 0.523V and 0L = 0L and 2.55 MOhms
D103 = 0.960V and 0.462V = 4.5 MOhms and 0L

D117 = 0.683V and 0L = 22.3 kOhms and same
D108 = 0L and 0.861V = 0L and 4.6 MOhms
D400 = 0.484V and 0L = 4.5 MOhms and 0L (this one if I jump it, my EVSEs respond with "Diode check failed"
D402 = 0.614V and 0.545V = 2.74 kOhms and same. This is connected through TP55 with C402, R400 and R419. TP55 one end is connected to the downstream (upstream is CN100), of D400
D619 - is closed circuit. Actually reading .000V and 0.00V with diode test.

Bottom side of Top board: (Left side positive first)
D112 = 0.697 and 0.696V = 3.51 kOhms and same
D110 = 0.476V and 0.476V = 1.75 kOhms and same
D115 = 0L and 0L = ~1.5 Mohma and 0L
D5111 = 0L and 0L = ~2.0 Mohms and 0L
D105 = 0.472V and 0.885V = 39.4 kOhms and same
D5110 = 0L and 0L = ~3.8 MOhms and 0L
VS5101 = 0.683 and 0L = 22.1 kOhms and same

D640 = 0L and 0.653V = 0L and ~12 MOhms
D121 = 0L and 0.951V = 100 kOhms and 100 kOhms

D126 = 0L and 0L = 100 kOhms and 100 kOhms

 

[kennybobby]

For diodes and transistors, check using the diode function.

For transformers, check using resistance.

Suspicious of diode reading the same in both directions, or no reading. There may be some conformal coating on the board that would need to be cut thru in order to make connections.

 

[evVanagon]

For diodes and transistors, check using the diode function.

Yes, that's what i'm doing. It's very odd to see voltages read in both directions or no voltages at all. These componetns i've measured multiple times to make sure before writing the value down.

For transformers, check using resistance.

Right and both sides of a transformer should have 0 resistance and across the terminals of a transformer they should be open

Suspicious of diode reading the same in both directions, or no reading. There may be some conformal coating on the board that would need to be cut thru in order to make connections.

I am very suspicious on this as well. Regarding the coating. I'm very aware of this and i'm testing againt the TP (test points) to make sure I have a good connection. If the TP point and the component pad have continuity then i know

 

[kennybobby]

Can you read the part numbers of the diodes which have strange readings, e.g. open both directions, time to look up the datasheets.

 

[evVanagon]

D126 seems to be a GND protection diode. It's connected to Pin 7 of CN100 and therefore Pin 10 of F23 (pdm connector). And from above i'm reading no volts in any directions and reading 100 kOhms in both directions.

IC504 is QC Can Transceiver with part number: TJA1040T - TJA1040T High-Speed CAN Transceiver
IC600 is Charger's EV Can Transceiver, same part number.

Can you read the part numbers of the diodes which have strange readings, e.g. open both directions, time to look up the datasheets.

Too small. Can't see any markings.

Here's some more info.

D112 = 0.697 and 0.696V = 3.51 kOhms and same = Pin 21 on F23 = Pin 10 on chademo or Pin 2 in nissan's manual (charger start/stop 1) - Goes somewhere
D110 = 0.476V and 0.476V = 1.75 kOhms and same = Pin 22 on F23 = Pin 3 on chademo or Pin 1 in nissan's manual (unknown) - Goes somewhere
D115 = 0L and 0L = ~1.5 Mohma and 0L = Pin 20 on F23 = Pin 7 on chademo connector or Pin 3 in nissan's manual (connection check). Only goes to Ground.
D5111 = 0L and 0L = ~2.0 Mohms and 0L = Pin 15 on F23 = to Resolve VCU pin 15 - Interlock OUT - Goes somewhere
D105 = 0.472V and 0.885V = 39.4 kOhms and same = Pin 29 on F23 = Proximity Detection - CONDETI - White - J1772 Pin 2 in nissan's manual - Only goes to Ground.
D5110 = 0L and 0L = ~3.8 MOhms and 0L = Pin 12 on F23 = To Resolve VCU pin 31 - Interlock IN - Goes somewhere
VS5101 = 0.683 and 0L = 22.1 kOhms and same = Pin 25 on F23 = Pin N/A or Pin 10 in nissan's manual - QCTemp2. - Only goes to Ground.

...except D400 on top-side of board. This is the diode that EVSEs check against. (diode check function) has markings of G2 on it.

 

[evVanagon]

Top-side of charger, top of the bottom control board.

D201 - 0.010V both direction - Markings: EH4 4110
D200 - 0.010V both direction - Markings: EH4 4110
D204 - 0.010V both direction - Markings: EH4 4110

D206 - 0.413V forward and 0L reverse - Markings: UM 3C

D253 - 0.440V forward and 0L - Markings: 88 3A
D254 - 0.440V forward and 0L - Markings: 88 3A

Also note:
I just got confirmation that Isak at Resolve-EV downloaded the newest version of LeafSpy Pro that shows DTCs from the Charger ECU and when his car successfully charges the U100A message is present.

Also, did some investigating with the 0.5-2A ghost draw on the HV battery.

• This happens with IGN ON where CAN can be read into LeafSpy. Same draw happens even if the Charger PDM F23 connector is disconnected and even if the Service Plug is disconnected. This seems alarming to me. No voltage at the PDM HV input. Maybe there is a weld that happenned in the HV battery?
• With the service plug disconnected AND Charger connected, i get DTC 2980- DC/DC Converter - This is because there is no HV voltage at the input to the charger. Makes sense.

Also got the latest SavvyCan version to start graphing properly on Mac OS.

 

[kennybobby]

For the diodes that read the same both directions, or shorted, or open--you might be able to use your soldering iron to wick away some solder and lift one end off the board. Then recheck the diode function. If you remove one entirely from the board just be sure to mark the part and the board to get it back in the correct direction.

 

[evVanagon]

Another update:
Got the HV battery upper case separated. Found the current sensor. Disconnected it by the low voltage connection and LeafSpy reports unreadable values so this tells me the LB_Current is coming from this exact current sensor. Then reconnected the low voltage signal connection and disconnected the bus bar it surrounds. With the bus bar disconnected LeafSpy still reports 0.5 to 2A draw. Im inclined to beleive this current sensor is broken and reporting false values. Which im hoping is the root cause of my no charging power symptoms.

Part #294G0 3NF0A 1210080139

 

[evVanagon]

Part #294G0 3NF0A 1210080139
Terminal 1 on the Left of the part.

Current Sensor LB5 from pg. EVB-27
Terminal 1 = unknown
Terminal 2 = V
Terminal 3 = G
Terminal 4 = S

1 to V = 10 MOhms and gets smaller
1 to G = 5.65 kOhms
1 to S = 169 ohms

V to G = open, manual states it should be = 1 kΩ–10 MΩ - ❌
V to S = 17MOhms and gets smaller quickly

G to S = 5.78 kOhms - manual states it should be = 1 kΩ–10 MΩ - ✅

 

[evVanagon]

Got the current sensor apart. I'm still going to try and replace some individual components before purchasing a new sensor.

Hall Sensor: 817A 2225. Other numbers illegible. Best guess is: 14K07328
Other component: PET1

This part number is discontinued at Nissan dealerships. You can still get this whole unit from a few parts dealers online and rockauto.com even.

 

[kennybobby]

i'm guessing V=power supply voltage, G=ground/return, and S=Signal;

What are the pins in your picture, where is pin 1? What is on the other side and what components are under the black coating?

You might check continuity of the hall sensor leads numbered left to right, 1 goes to Vcc supply, 2 goes to return, 3 is the Output signal that may be an input to an op amp chip.

PET1 may be a TPS79147DBVRQ1, a low drop out voltage regulator chip, 4.7V 0.1A, datasheet

Check if pin 5 of PET chip goes to pin 1 of the hall sensor.

 

[evVanagon]

What are the pins in your picture, where is pin 1? What is on the other side and what components are under the black coating?

Under black coating is a capacitor next to Pin 3 of Hall sensor, and below that is just a 0 Ohms resistor. Doesn't have a "0" marking tho.

You might check continuity of the hall sensor leads numbered left to right, 1 goes to Vcc supply, 2 goes to return, 3 is the Output signal that may be an input to an op amp chip.

No continuity, and no other components to this board. Except a 0 Ohm resistor on the back. The Op amp chip you suggest might then be inside the LBC.

• Terminal 1 to 3 of Hall sensor = 168.9 Ohms
• 1 to 2 is open
• 2 to 3 is open

Check if pin 5 of PET chip goes to pin 1 of the hall sensor.

Yes that's true it is connected to Pin 1 of Hall sensor

 

[evVanagon]

Just got some live readings.

Current sesnor - LB5 connection
Voltage to Ground = 5.08V
Signal to Ground = 3.16V (not connected to anything, no bus bar attached to HV battery)

Then on the PCB. Pin 1 of the PET voltage regulator gets 5.08V, and the output on Pin 5 is 4.69V exact. Same at Pin 1 of Hall sensor.


then from manual,
Terminal 10 to 15 of LBC's LB11 connection = 3.96 kOhms but should be ~4.7 kOhms. It's cold out, 0C inside the battery case (from Leafspy)

• Terminal 10 connects to Signal of current sensor.
• erminal 15 connects to Ground of current sensor

 

[evVanagon]

My best guess at the Hall Sensor is this: HAL817 with temperature marking of A meaning up to 170 degrees C.

HAL817 pdf, HAL817 Description, HAL817 Datasheet, HAL817 view ::: ALLDATASHEET :::

HAL817 Datasheet, HAL817 datasheets, HAL817 pdf, HAL817 integrated circuits : MICRONAS - Programmable Linear Hall-Effect Sensor ,alldatasheet, Datasheet, Datasheet search site for Electronic Components and Semiconductors, integrated circuits, diodes, triacs and other semiconductors.

pdf1.alldatasheet.com

 

[kennybobby]

If you can power up the little board with a power supply, then monitor the Output Signal while moving a small magnet in and out from the surface of the hall sensor you should see the voltage change. Also flip the magnet over to use the opposite polarity and repeat the test.

 

[evVanagon]

If you can power up the little board with a power supply, then monitor the Output Signal while moving a small magnet in and out from the surface of the hall sensor you should see the voltage change. Also flip the magnet over to use the opposite polarity and repeat the test.

• Test this on a bench with 5.0-5.1V from RPI. Moving magnet over drops output voltage from 3.16V.
• Tested this in the HV battery and LB_Current reflects the magnet.
• Video of LeafSpy => RPReplay_Final1676009981.mov

My guess is maybe this Hall sensor has become uncalibrated.