Circuit Boards · The circuit consists of the following blocks : ・Input Filter AC source ( 100V /...
19
・Circuit Boards Top view Dimensions Area No. of layer Board thickness Weight Power Supply Board (W) 204.4mm (L) 137.7mm 281.5cm² 4 (t) 1.7mm 512.6g Control Board (W) 245.3mm (L) 131.4mm 322.3cm² 4 (t) 1.6mm 167.0g Filter Board (W) 276.9mm (L) 62.0mm 171.7cm² 4 (t) 1.7mm 319.0g Driver Board (W) 79.9mm (L) 53.8mm 43.0cm² 4 (t) 1.6mm 23.6g
Transcript of Circuit Boards · The circuit consists of the following blocks : ・Input Filter AC source ( 100V /...
・Circuit Boards�
Top view Dimensions Area No. of layer
Board thickness Weight
Power Supply Board
(W) 204.4mm(L) 137.7mm
281.5cm² 4 (t) 1.7mm 512.6g
Control Board
(W) 245.3mm(L) 131.4mm
322.3cm² 4 (t) 1.6mm 167.0g
Filter Board(W) 276.9mm(L) 62.0mm
171.7cm² 4 (t) 1.7mm 319.0g
Driver Board(W) 79.9mm(L) 53.8mm
43.0cm² 4 (t) 1.6mm 23.6g
2. Circuit boards and modules
Power Supply Board
4-layer through-hole.Layers are structured as follows :The board is screwed with the case at 9 portionsThe screwed portions are not through-holed.
Control Board
Board X-ray (Side View)
Board X-ray (Side View)
※ Detailed dimensions are available in the paid version of the report
Thickness L/S [mm] Min. through-hole dia.[mm] Layout
Solder resist Resin -
Copper-plated layer
Copper foilInsulation layer between L1-L2 Resin ＋ 2 sheets of glass cloth -
L2 Copper foil
Insulation layer bet. L2-L3 -
L3 Copper foil
Insulation layer bet. L3-L4 -
Copper foil
Solder resist Resin -
Overall thickness of substrate SR(on L1 circuit) to SR(on L4 circuit) -
Thick. of through-hole plating Copper-plated layer -
Inner dia. of through-hole plating - -
Layer structure
L1
L4
Thickness L/S [mm] Min. through-hole dia.[mm] Layout
Silk-screen Resin -
Solder resist Resin -
Copper-plated layer Copper foil
Resin ＋ 2 sheets of glass cloth -
L2 Copper foilResin ＋ 5 sheets of glass cloth -
L3 Copper foilInsulation layer bet. L3-L4 Resin ＋ 2 sheets of glass cloth -
Copper foil
Copper-plated layerSolder resist Resin -
SR(on L1 circuit) to SR(on L4 circuit) -
Copper-plated layer -
- -
Layer structure
L4
L1
Resin ＋ 5 sheets of glass cloth
Resin ＋ 2 sheets of glass cloth
Copper-plated layer
Insulation layer between L1-L2
Insulation layer bet. L2-L3
Overall thickness of substrate Thick. of through-hole plating
Inner dia. of through-hole plating
4-layer through-hole.Layers are structured as follows :The board is screwed with the case at 9 portionsThe screwed portions are not through-holed.
3. CircuitThe circuit consists of the following blocks :
・Input FilterAC source ( 100V / 200V) for battery charging is applied.
・Input Voltage MonitorThe circuit to monitor the voltage of AC source from external.2 types of input voltage, one upstream of power relay (4019)・(ACIC2,ACIH2) and the other downstream(ACIC3,ACIH3), are transferred to "Charge MCU Block" through the filter consists of the operational amplifiers(2505,2510) each.
・PFC Voltage Monitor
・PFC ControlThe circuit to control "PFC Driver" in conjunction with the current sensor output (4035) from "Input Filter",monitoring the output of the current sensor (4035) remains between the current values specified by "ChargeMCU Block" utilizing the operational amplifiers (2500_3,2500_4).The result of the monitoring is input to "Charge MCU Block" and enables to stop "PFC Driver" via. the logic IC(2606_1,2606_2).
Overview
300.3 mm
229.
6mm
Overall weight: kg
80.2 mm
Fig. 1-1 Dismantling 1
Top side cover
Control circuit board
Insulation sheet
Fig. 1-2 Dismantling 2
Insulation & heatradiation rubber 1
Heat radiation rubber 8
Insulation & heatradiation rubber 2
Heat radiation rubber 9
Fig. 2-1 Power Source Board apparance
204.4mm
137.
7mm
Bottom View
Top View
Weight: 512.6g
Fig. 2-2 Control Board appearance
245.3mm
131.4
mm
Bottom View
Top View
Weight: 167.0g
Fig. 3 Power Source Board, mounted components (partial)
Elements
Blue : Mounted position・ corresponding to Parts List Black : Terminal No. Red : Terminal No. (w/o terminal)
0013,0018
2 1
2
3
1
0021
1 3
2 0024 0032,0038
A K
G
D
S
0035,0039 0042,0043,0044
2
1
Top View
1
3
2
4
0030,0054
1
2 3
4
0031
Top View
1
5
4
6 1
2
5
6
3
4
0029
Top View Bottom View
6 1
7 12
Equivalent Circuit
1
2
4
5
6
3
9
8
7
10
11
12
Equivalent Circuit
Equivalent Circuit
Bottom View
Top View
Fig. 4 Contriol Board, Analysis Area
⑮
⑯
⑫
⑩
⑭
⑬ ⑳
⑧
⑪
⑱
⑦
⑲
⑨ ⑦
⑧
⑬
⑳
⑯
⑮
⑮
⑫
⑱
⑲
⑧
⑦
⑨
⑪
⑩ ⑰
Analysis Area
Function
7 Power Switch 14 Charge Protection1,PFC Control
8 Internal Power Supply 15 Charge Protection2
9 Communication 16 PFC Driver,DC/PSFB Pre-Driver
10 Communication MCU Block 17 PFC Voltage Monitor
11 Power Supply Custom ASIC Block 18 Output Voltage Monitor
12 Charge MCU Block 19 LLC Pre-Driver
13 Input Voltage Monitor 20 Relay Control
Fig. 5 Control Board, positions of components (Top View)
Components Mounted Position
NM : No Mount
2002
20
03
20
04
2005
2006 2007
20
08
2009 2010
2011 2012
2013
20
14
2015
20
16
20
17
20
18
20
19
2020
2021
20
22
2023
2024 2025
2026 2027 2028
20
29
2
03
0
20
31
20
32
2033 2034
2035 2036
2037 2038
2039 2040
20
41
20
42
20
43
2
04
4
20
45
2046
2047
2048 2049
2050
2051
2052
2053 2054
2055
20
56
20
57
2058
2059
2060
20
61
20
62
2
06
3 20
64
20
65
2066
2067
2068
20
69
2070
20
71
2
07
2
20
73
20
74
2075
2076
2077
2078
2079
20
80
2081
2082
20
83
2
08
4
20
85
20
86
2087 2088 2089 2090
2091
2092
2093
2094
2095
2096
2097 20
98
2099
2100
2101
21
02
2103 2104
2105
21
06
2
10
7
2108 2109
2110 2111
2112 2113
2114 2115
2116
2117
2118
21
19
2
12
0
21
21
21
22
2123
2124
2125 2126
2127
2128
2129
2130
21
31
21
32
2133
21
34
21
35
21
36
2137
21
38
21
39
2
14
0 2
14
1
21
42
21
43
21
44
2
14
5
21
46
2
14
7
21
48
21
49
21
50
2
15
1
21
52
21
53
21
54
2155
2156
21
57
2
15
8 2
15
9
21
60
2
16
1
21
62
21
63
2164
2165 21
66
2
16
7
2168 2169 2170 2171
2172 2173
2174
2175
2176
2177
2178
21
79
2180 2181 2182 2183
21
84
2
18
5
21
86
2
18
7
21
88
2
18
9
21
90
2
19
1
21
92
2
19
3
21
94
21
95
2196 21
97
21
98
2
19
9
2200 22
01
2
20
2
2203 2204
2205
2206
22
07
22
08
2
20
9
2210
22
11
22
12
22
13
22
14
22
15
22
16
2217
2218
2219
22
20
2
22
1
22
22
2223 2224
2225
2226
2227
2228
2229
2230
2231
2232
2233
2234
2235
2236
2237
2238
2239
2240
22
41
22
42
2
24
3 2
24
4 22
45
2
24
6
2247 2248
2249
2250
2251
2252
2253
2254
2255
2256
2257
2258
22
59
22
60
22
61
2262
2263
22
64
22
65
2266
2267 2268
2269 2270
22
71
2
27
2
2273
2274
2275
2276
2277
22
78
22
79
22
80
22
81
22
82
22
83
22
84
22
85
22
86
22
87
22
88
22
89
22
90
22
91
22
92
22
93
22
94
2295
22
96
2
29
7
2298
22
99
2
30
0
23
01
2302
23
03
2304
23
05
2306
2307 2308
2309
23
10
23
11
2312
23
13
2314
2315
2316
2317 2318
23
19
2
32
0
23
21
2322
23
23
2324
23
25
2
32
6
2327
23
28
2
32
9
23
30
23
31
23
32
2
33
3
23
34
2335 2336
23
37
23
38
23
39
2340 2341
23
42
23
43
2344 2345
2346
2347 2348
23
49
2350
2351 23
52
2353
23
54
2355
23
56
23
57
2358
23
59
2360
2361
2362 2363
2364
2365
23
66
23
67
2
36
8
23
69
2370
2371
2372
2373
23
74
23
75
2
37
6 2
37
7
23
78
2
37
9
23
80
2381
2382
2383 2384
2385
2386 2387 2388 2389 2390 2391
23
92
23
93
2394 2395
2396
2397 2398 2399
2400
24
01
24
02
24
03
24
04
2405
24
06
2
40
7
24
08
2409
24
10
2
41
1
2412
24
13
2
41
4
24
15
2416 2417 2418
2419
24
20
2
42
1 2422
24
23
2
42
4
2425
2426
24
27
2428
2429
2430
2431
2432 24
33
24
34
24
35
2436 2437
24
38
2
43
9
2440
2441
24
42
2443
2444 2445
24
46
24
47
2448
24
49
2
45
0
24
51
24
52
24
53
24
54
24
55
2
45
6
2457
24
58
2459
24
60
2461
24
62
2463
24
64
24
65
24
66
24
67
2468 2469
2470
2471 24
72
2
47
3
24
74
24
75
2476
24
77
2478
2479 24
80
2481
24
82
2483
2484
2485 2486
2487
2488
2489
2490
24
91
24
92
24
93
24
94
24
95
24
96
2497
2498
24
99
2500
2501
2502 2503
25
04
25
05
25
06
25
07
2
50
8
2509
2510
2511
25
12
25
13
2514
25
15
2516
2517 25
18
2519
2520 2521
2522 2523 2
52
4
2525
2526
2527
25
28
2529
25
30
25
31
2
53
2
25
33
2
53
4
2535
25
36
25
37
2538
2539
2540 2541
2542
25
43
25
44
25
45
2
54
6
25
47
2548 2549 2550
25
51
25
52
25
53
25
54
2555
2556
25
57
2558
25
59
25
60
2561 25
62
25
63
2564
25
65
2
56
6
25
67
2
56
8
2569
25
70
2
57
1
25
72
2573 2574
2575 2576
25
77
2
57
8 2579
2580
2581 2582 2583
2584
2585
2586 2587 2588
2589
2590
2591 25
92
25
93
25
94
25
95
25
96
2597 2598 2599 2600 2601
2602
2603
26
04
2605
2606
2607
26
08
2609 26
10
2611
2612 2613 2614
2615 2616
2617
2618
26
19
26
20
2621
26
22
2
62
3
26
24
26
25
2626
26
27
2
62
8
26
29
2630
2631
2632 2633 2634
2635
26
36
2637
26
38
2639
26
40
2641
2642
2643 2644 2645
26
46
2647 26
48
26
49
2650
2651
26
52
2653
26
54
2655
26
56
2657 2658
2659
26
60
26
61
26
62
26
63
2
66
4
26
65
26
66
2667
2668
2669 2670 2671
2672
26
73
26
74
26
75
26
76
26
77
2678 2679
2680
26
81
26
82
26
83
26
84
26
85
2686 2687
2688
26
89
26
90
26
91
26
92
2693
26
94
2695
2696 2697
2698
26
99
27
00
27
01
27
02
2703
2704
2705
2706
30
38
33
29
3382
3383
NM
20
01
NM
20
02
NM2003
NM2004
NM2005
NM2006
NM2007 NM2008
NM2009
NM2010
NM2011
NM2012
NM2013 NM2014
NM
20
15
NM
20
16
NM
20
17
NM2018 NM2019
NM2020
NM
20
21
NM
20
22
NM
20
23
NM2024
NM
20
25
NM
20
26
NM2027 NM2028
NM2029
NM
20
30
NM
20
31
NM2032
NM
20
33
NM2034
NM2035 NM2036
NM2037
NM
20
38
NM2104
NM
21
05
NM2106
NM
21
07
Components Information (partial)
No Silk Marking Supplier Function Nominal Measure Remark
0001 VCHG+ - - Connector 1pin
between Power Source Board & External Connector 3
- inference
0002 VCHG- - - Connector - inference
0003 - - - Connector - inference
0004 - - - Connector 1pin
FG terminal - - inference
0005 + - - Connector
1pin
between Power Source Board & Diode Module
- - inference
0006 - - - Connector - - inference
0007 - - - Connector 1pin
between Power Source Board & Transformer
- inference
0008 - - - Connector - inference
0009 VH+ - - Connector - inference
0010 VH- - - Connector - inference
0011 - IRS
B5
IRISO ELECTRONICS
Connector
7pin
between Power Supply Board & Driver Board
- inference
0012 - IRS PA9T
C1
IRISO ELECTRONICS
Connector
26pin
between Power Source Board & Control Board
- inference
0013 -
2R5L
781
113
- Inductor 2.5u H 2.582u H inference
1pin
between Power Source Board & External Connector 3
1pin
between Power Source Board & External Connector 3
1pin
between Power Source Board & Diode Module
1pin
between Power Source Board & Bus bar
1pin
between Power Source Board & Bus bar
1pin
between Power Source Board & Bus bar
Fig. 6 Power Source Board, connectors
Interfaces
Top View
0011
6
1 2
7
0008
0009
0010
0001
0002
0004 0003
0005 0006 0007
1 1
0012
1
26 25
2
1
1
Blue : Mounted position・ corresponding to Parts List Black : Terminal No.
※1 SR = Solder resist※2 Embedded resin = resin for sample fixing※3 TH = Through-hole
Section Analysis
(SR:00 um ※1)
[L4]
[TH※3]
[L2]
Prepreg[Insulation layer bet. L1-L2]
[L1]
[Embedding resin※2]
(SR:00 um ※1)
00 um
00 um
00 um
00 um
00 um
00 um
00 um
※2 copper-plated layers are formed
[L3]
00 um
00 um
00 um
Core material [Insulation layer bet. L2-L3]
Observed Direction
Sectioned Portion
Fig. 7 Power Source Board, dimensional measurement on section
Prepreg[Insulation layer bet. L3-L4]
Measured Dimensions of wiring
Fig. 8 Control Board L1, wiring dimensions
Top View
Top View
:Measured portion
L1 min. wiring width：00um L1 min. distance of wires：00um L1via. inner dia. 1：00um L1via. inner dia. 2：00um
Transformer
Fig. 9 Transformer, measurement
0029
Frequency at measurement：100kHz Measurement equipment: IM3523 by HIOKI
Top View
Bottom View
6 1 2 3 4 5
7 12 11 10 9 8
測定端子 測定結果
インダクタンス比 巻線比 結合係数 Open 測定端子以外Short
2-3 254.22uH 10.84uH 36.7 6.1 0.9784
3-5 176.72uH 7.20uH 25.5 5.1 0.9794
2-5 850.88uH 35.07uH 122.9 11.1 0.9792
7-9 6.96uH 0.06uH 1.0 1.0 0.9959
10-12 6.92uH 0.03uH 1.0 1.0 0.9977
Equivalent Circuit
1
2
4
5
6
3
9
8
7
10
11
12
*Inductance ratio, winding number arerounded to the first decimal place
Blue : Mounted position・ corresponding to Parts List Black : Terminal No. Red : Terminal No. (w/o terminal)
Fig. 10 Filter Board L1, measured dimensions
Top View
Top View
:Measured portion
0
FG
FG
0mm
ACIH
ACIC
0
Insulation Rules (board)
AC power side
case(FG)
case (FG)
0
0
Dimensions in mm
Insulation Rules (system)
AC power side
A
A’
B’ B
Schematic section, measured portions
B’ B
0
0
0
0 0
0
0
A A’
Dimensions in mm
Fig. 11 AC power side, measured results (partial)
0
0
0
Schematic section, measured portions
Fig. 12 heat Generating Components, locations (image)
Reactor (1004)
Transformer (1001)
Diode Module (1005) Inductor (1002)
Power Module
Electrolytic Condensor (0045～0053)
Transformer (0029)Inductor (0055)
Heat radiation structure
Line Filter (4017)
Bottom cover (Bottom View)
Line Filter (4026)
Schottky barrier Diode(0024)
: Heat-generating components
(touching cpmpo.s to bottom cover)
: Air-cooled zone
