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Re: [solectria_ev] Another Fixed Charger

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  • Wolf
    Page 10 in the Brusa NLG4B manual has more details. Wolf *wags his tail* www.wolftronix.com ... From: Wolf To: solectria_ev@yahoogroups.com Sent: Monday, May
    Message 1 of 4 , May 31, 2010
      Page 10 in the Brusa NLG4B manual has more details.

      *wags his tail*

      ----- Original Message -----
      From: Wolf
      To: solectria_ev@yahoogroups.com
      Sent: Monday, May 31, 2010 1:02 PM
      Subject: Re: [solectria_ev] Another Fixed Charger

      How did your friend get the caps off? What was used to remove the epoxy?

      What type of epoxy did he use to glue the caps back to the board?

      Different thermal expansion rates between the solder leads and epoxy is what causes the joints to fail.

      Also, I think I mentioned this before, but rather then reprogramming the charger, you can install a 5K pot between pins 5 and 6, then you can vary it from 0 to 100% mains current. So on cold days you can crank it all the way back up, and on hot days you can turn it back down. :)

      *wags his tail*

      ----- Original Message -----
      From: Joshua Goldstein
      To: solectria_ev@yahoogroups.com
      Sent: Saturday, May 29, 2010 2:51 PM
      Subject: [solectria_ev] Another Fixed Charger

      Hi Solectricians,
      The final report on my broken charger is that I got it fixed! It had
      the usual bad caps, which had even burned a small hole in the cap board, as
      well as some problems on the logic board and a balky fan. I found someone
      here in New England who was able to fix those problems (write me off list if
      you want their contact info). So it's now charging perfectly.
      However ... It's clear that the NLG4 runs too doggone hot, and I want
      to endorse Mike R.'s suggestion (list archives 9/3/2009) to reprogram it and
      turn down the input current. I reprogrammed my newly fixed charger down
      from 16A to 12A as the limit on the mains. (This is really easy if you have
      a DB9-capable computer and the free NGL_E.exe program -- see list archives
      or ask.)
      Even with the current limited to 12A I am recording internal temps
      during charging (80-degree day, trunk open) up to 84 C, which is 183 F.
      Given the problems of this charger design and how irreplaceable the NLG4
      seems to be in our cars, I don't really want to run it any hotter than that.
      However, if you needed a faster charge than I do (hasn't been an issue
      really; not that much slower), you might choose a higher current than 12A.
      Also, if anyone knows a reason it would _not_ be good for the charger to run
      a little slower and cooler, do speak up.
      Meanwhile congrats to Wolf for getting one of his working! Maybe it's a
      trend :-)
      Joshua Goldstein
      -99 Force

      Dear Forcies,
      It took a while but I got someone to replace the bad caps in my NLG4
      charger as well as several other problems on the logic board, and now the
      charger is working (!) -- except for a balky fan that I still have to get
      fixed. So I'm up and running, except...
      I want to reprogram the charger with the NLG_E program, to reduce the
      maximum input amps so as to avoid overheating. This is Mike R.'s excellent
      suggestion (archives 9/3/2009). However, the program is giving me trouble.
      It starts up and says "Transmission successful" and has the profile loaded.
      But when I try to run any of the functions in the top left box -- reading or
      writing to the charger -- it says "value missing or wrong" and then
      "Transmission abborted."
      As a note about the overheating, I'm getting internal temps up to about
      85C during stage 1 with the fan running and not a hot day, drawing 15-16A
      from the line. Don't know what it's supposed to be but I consider that too
      hot and once the input amps drop later in the stage the temp does too.
      (I've been unplugging and letting it cool down a while when it gets above
      75C. Reprogramming would be a lot more convenient!)
      Anyone have an idea or have you run into this message??
      Joshua Goldstein
      '99 Force

      ----- Original Message -----
      From: "Wolf" <wolf@...>
      To: <solectria_ev@yahoogroups.com>
      Sent: Monday, January 25, 2010 9:06 PM
      Subject: Re: [solectria_ev] Another Broken Charger

      >I could possibly have a good cap board... In the "broken" charger row:
      > http://www.wolftronix.com/BC3300/IMG_6705.JPG
      > However, since the cap board seems to be the most likely problem with the
      > BC3300, they probably all have bad cap boards too. :/
      > I have not taken any apart yet to see what is wrong with them (have not
      > had the free time yet).
      > This chronicles the repair of a BC3300, but it was not one from the row:
      > http://www.wolftronix.com/BC3300
      > It was one sent in for repair...
      > Wolf
      > *wags his tail*
      > www.wolftronix.com

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