July 2009


One of the most sobering tests performed by a guy making his own BMS is here. His experiment showed that using the wrong parts can in deed cause a fire. Several designs out there use these same parts.

In another post, this poor fellow had his whole car burn to the ground. What a shame. He did a lot of work on it.

Here is a Prius fire story using A123’s. A bad connection was suppose to be the culprit of that disaster.

This P1 Dolphin board has the Mach220 chip that’s seriously damaged and the main relay fet vaporized from the board. Both instances left some low impedance paths between some traces. The Mach220 removal solved many of them. But the fet traces are damaged inner layers of traces. So the fet will have to be isolated and jumpered back into the circuitry.

All of the power supplies work with the Mach220 removed. So now the debug process starts. With a massive pile of projects on my plate, I don’t know how much more work this board will get until I have more of the projects completed.

This is how the board arrived. The 5v rail powered this Mach220 to death. Amazingly the 5v reg still works.

Here is what a correctly removed Mach220 location looks like. Zero lifted pads or traces. A socket will get installed here.

This fet had to have been jumpered to try and operate the main contactors directly. This is what happens.

The board did not squeal when it was tested again. It works fine now.

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