FtWorthKat
Posts: 9
Joined: Fri Oct 27, 2017 10:07 pm

Re: Charging Fault error.

Thu Dec 14, 2017 11:48 pm

I just got the charging fault error very late on 12/12/17 and continued to get this error several charging attempts in a row where the car's LEDs wouldn't light up and the level 1 charger would say it was charging for a minute and then click off. Only once of these attempts the level 1 charger also reported a charging fault. I already had a service appointment for the morning of 12/13/17 for something less serious, so I took my car in to Southwest Kia of Dallas. No Dallas/Fort Worth area dealer is "EV certified" but I bought the car from Southwest Kia of Round Rock (near Austin) and the Dallas dealership seems willing to coordinate the transport of my vehicle with Kia and support me with a loaner car. (Dallas wanted to do the warranty work too, but apparently Kia said no.)
So on 12/14/17 my vehicle was transported from Dallas to Round Rock; nobody told me this, but I discovered on the UVO app where it reports a 0.6 mile trip from 6:44 to 6:45 from point A in Dallas to point B in Georgetown TX. (A-B actually being 161 miles apart) At this point I do not have a timeline for this repair and I am a bit nervous about it potentially impacting some travel plans, but so far so good.

JejuSoul
Posts: 1220
Joined: Wed Jul 08, 2015 6:47 am
Location: Jeju
Contact: Website

Re: Charging Fault error.

Thu Feb 15, 2018 1:39 am

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First report of a failure in a MY2018 car here - New 2018 Soul EV with Onboard Charger Failure
The codes for using Torque Pro can be found by clicking the link in the website icon under my user name on the left.

Nael
Posts: 2
Joined: Tue Apr 17, 2018 5:58 am

Re: Charging Fault error.

Tue Apr 17, 2018 6:29 am

Hi All

I have discovered and solved the charger (OBC) problem in Soul EV
it's need to change some parts in the OBC

notfred
Posts: 316
Joined: Thu May 07, 2015 2:28 pm

Re: Charging Fault error.

Tue Apr 17, 2018 8:56 am

This is interesting, can you clarify what parts need changing?

Nael
Posts: 2
Joined: Tue Apr 17, 2018 5:58 am

Re: Charging Fault error.

Thu May 03, 2018 5:01 am

H
Last edited by Nael on Sun May 13, 2018 6:04 am, edited 1 time in total.

JejuSoul
Posts: 1220
Joined: Wed Jul 08, 2015 6:47 am
Location: Jeju
Contact: Website

Re: Charging Fault error.

Wed May 09, 2018 9:57 pm

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Kia have never acknowledged that there is a problem with the OBC unit so the following is entirely speculation.

1. There is a problem that maybe has a 50-50 chance of occurring in the first 4 years of owning the car. It is 'fixed' by replacing the OBC.

2. The problem is caused by hairline fractures in the cooling pipes allowing liquid coolant to leak onto the electronics.

The inlet for the coolant looks like this.

Image

If this is true, then a simple fix is obvious. Don't run coolant pipes through the electronics.

Here's a photo of the new K ona EV. You can see the coolant reservoir (green on the right) and the water pump ( on the left).
Very similar to the system on our cars.

Image

But the new motor and electronics look like this. There are no coolant pipes going into the electronics.

Image

A speculative theory is that the coolant is used to cool the battery not the OBC and EPCU.
Last edited by JejuSoul on Sun Jul 08, 2018 9:27 am, edited 1 time in total.
The codes for using Torque Pro can be found by clicking the link in the website icon under my user name on the left.

JejuSoul
Posts: 1220
Joined: Wed Jul 08, 2015 6:47 am
Location: Jeju
Contact: Website

Re: Charging Fault error.

Thu May 31, 2018 9:56 pm

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Amazing video by Rich Rebuilds showing him taking apart a T esla M odel S OBC.
It is really difficult to access, and very, very difficult to take apart.
They use multiple hammers and a heavy duty plasma torch!

https://www.youtube.com/watch?v=9XZEDHv9l2k

You can see the inlets for the liquid coolant. I assume it's glycol like ours, but dyed blue.
Image

There is a heavy aluminium base plate below the main unit that was firmly glued to it, the coolant lines are on the underside of the main unit.
Image


The main conclusion. The T esla OBC is over-engineered. It is much more expensive to build than ours.
If it went wrong it would be really expensive to service.
Our OBC however is easy to access, and to replace if something does go wrong.

However the coolant lines on our OBC are inside the main unit. If it leaks, this is a major problem.

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Here's a video by T eslaBjorn discussing an OBC failure on a T esla M odel S

https://www.youtube.com/watch?v=Yeq8zLOvws4

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The codes for using Torque Pro can be found by clicking the link in the website icon under my user name on the left.

JejuSoul
Posts: 1220
Joined: Wed Jul 08, 2015 6:47 am
Location: Jeju
Contact: Website

Re: Charging Fault error.

Sun Jul 08, 2018 9:41 am

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It seems the number of cars requiring new OBCs is much lower than before.
Perhaps most of us have had a replacement by now and these newer OBCs are working.

This thread is one of the longest and probably contains the most useful info on this forum.
But it is now too long for anyone to reasonably go through.
Also the search functionality on this site is awful. To find anything it is quicker and more effective to use Google.
Hence I am considering starting a new thread which has a first post that summarizes everything here.
Until I do I will just add interesting videos I find about other EVs and the OBC to keep bumping up this thread into the list of current pages.

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Here's an interesting video from New Zealand about fixing a faulty OBC in a N issan L eaf.

https://www.youtube.com/watch?v=5R4dGg8nIUs

In the previous cases of this fault that we are aware of, the solution was always to replace the entire on-board ch arger. However, when we were asked to diagnose and repair a 2011 N issan L eaf that had a charging fault we decided to take a look at what was actually failing in these ch argers. As it turned out, it was able to be fixed for less than a dollar worth of parts. The ch arger still needed to be completely removed from the vehicle for the repair, but that would needed to be done for a ch arger replacement anyway. We hope that this video helps other people from around the world with the same problem. PLEASE NOTE: The high voltage system on electric vehicles needs to be treated with extreme caution - we recommend this repair is only undertaken by people with the knowledge and experience to work on these vehicles safely.


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Last edited by JejuSoul on Tue Aug 28, 2018 10:22 pm, edited 2 times in total.
The codes for using Torque Pro can be found by clicking the link in the website icon under my user name on the left.

gally74
Posts: 1
Joined: Tue Aug 07, 2018 12:23 pm

Re: Charging Fault error.

Tue Aug 07, 2018 12:26 pm

Hello,

I can charge fine on CHADMO, the granny lead and also my own tethered 16 AMP home charger.

However if I plug into a 6KW charger with my own lead supplied by kia, it stops charging.....

Does this look like an lead issue or an OBC issue, thanks, Car is a late 15.

Pete

JejuSoul
Posts: 1220
Joined: Wed Jul 08, 2015 6:47 am
Location: Jeju
Contact: Website

Re: Charging Fault error.

Mon Sep 17, 2018 7:18 pm

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gally - sorry for missing your question - did you ever get it sorted?
The codes for using Torque Pro can be found by clicking the link in the website icon under my user name on the left.

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