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Old 09-02-2013, 05:51 AM   #6223 (permalink)
EcoModding Apprentice
Join Date: Oct 2009
Location: Jyvaskyla, Finland
Posts: 143

Golfwagen - '89 Volkswagen Golf mk2
90 day: 107.14 mpg (US)
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Do you have old style copper power board? I had it fail similarly even though precharge circuit worked. Voltage at terminals wouldn't rise as there was "load" at controller. Load was a small short on power board and when I forced main contactor on it resulted in smoke and molten copper too. You might need to replace some power components. I believe your repair bill will be small; new style power board and replace all the broken components. I'd replace everything just in case but it might not be necessary. Similar short should not happen anymore with newer style power board. This quick capacitor charging reduces its life.

Sometimes my precharge contactor simply refuses to operate. I monitor pack voltage at controller terminals so I know what is going on with precharge. If voltage doesn't rise as expected I cycle ignition key and precharge sequence starts over. Too bad this 500A controller doesn't actually know when precharge is actually done. Newer control board (1000A version) can monitor voltage if I'm not mistaken. This missing functionality doesn't bother me though.
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