As noted in Oztules EPIC "guess who bought a power jack inverter" thread, my Mainboard popped a bunch of mosfets and I'm now installing replacement Main/Control boards. I've hit a few bumps however, which I've asked the supplier about per the below 4 points and corresponding images.
If anyone out there in anotherpower land can share their own advice/experiences on these points or board swaps in general that would be greatly appreciated!
Also, a few notes that might help others...
- If you had old boards (i.e. LW-CONTROL-REV 1 and LFPSW-MAIN-BOARD REV:1.4) and are replacing them with new ones (i.e. V2.2/V2.2a boards) you will need to drill new mount points into the aluminum chassis as they don't align with the old boards mounts.
- You'll also want; a good scalpel/hobby knife set to cut all that horrible red glue off the various sockets/plugs; and a hot glue gun for reattaching the Bty Volt/ LED board to the chassis front panel (a pain I know... screw mounts would have been much simpler!
- Interesting to note the old Mainboard had 3 Caps (18000uF-50v) whereas the new board had 4...
- Finally, when I removed the end panel containing the battery teriminals/cooling fan, I found burn marks on the bottom screws/aluminum chassis!!!
It appears to have had a short across the terminals/through the chassis at some stage. Could that have been the root cause of my fet-pops? Any ideas on how best to prevent this in future (strips of electrical tape on the chassis, cover the bottom terminals in some non-conductive coating)?1.
I can see the Thermistor/Thermostat transformer connections on the new control board, however there a third connection thats soldered to the middle of the board with an eye terminal on the end of it (per the ? ? ?
) . This wasn't on the old control board and it's not obvious what it's for. Can you advise what this is for and where it's to be connected to?2.
Per the photo's the old Thermistor/Thermostat wires were soldiered directly to the control board and then held with a hot glue gun. Then they were stuck to the transformer with a black glue/resin. Also the wires on the new Thermistor/Thermostat are too short to actually reach the transformer. How would your engineer recommend I make this connection?
My thought is the easiest way would be to use the existing Thermistor/Thermostat glued to the Tranny, cut the wires connecting them to the old Control Board, then crimp these wires to a new set of the small white 2 pin plugs used on the new boards. Then I can simply plug them in.
Does your engineer see any issue with using the existing Thermistor/Thermostat in this approach and/or would he recommend another approach? Also can you tell me what those small white 2 pin plugs are called so I can order some off e-bay, or could you ship me a new pair?3.
My final hurdle is with the cables connecting the terminals. The new Mainboard has 4 x strands of 8AWG power cable
soldered to the board and then paired off and crimped into 2 x eye terminals for screwing down to the 2 x negative (-) battery terminals. The same existing positive (+) power cables however are 10AWG. This mismatch could obviously pose issues. Can you ship me a new pair of 8AWG positive power cables?4.
I also note that the two cable bundles coming out of the transformer each consist of 3 x strands of 10AWG power cable. One yellow the other black. Can you engineer advise if there will be any issues here considering the new Mainboard's use of 8AWG cable for the battery terminals? Any advise appreciated.