Chevy Volt Gen 2 charger 24281923

[arber333]

I just got one of Volt gen 2 chargers. It is a cute little unit with impressive 3.6kW power rating. Liquid cooled of course.
Immediately i tested every connector that i had available.

1. LV control connector is Molex MX150 P/N 33472-1201
It uses 6 pins out of 12. Pins are Molex MX150 F 18-20AWG P/N 33012-2002
https://www.molex.com/molex/products/fa ... tor_system

2. I am fairly certain HV battery side connector is TE HVA280 P/N 2103628 Key A 2 pole connector
https://www.te.com/usa-en/product-YHVA2 ... rce=header

ENG_CD_2103176_A-2026828.pdf

(527.66 KiB) Downloaded 886 times

3. It seems this is Delphi or Aptive HES 6 Way Device Connector Type 103. P/N 13879048
Pins are P/N 13783301
https://ecat.aptiv.com/product/13879051

16-32a-on-board-chargers-a4-web.pdf

(320.98 KiB) Downloaded 970 times

[EV_Builder]

Thank u for sharing

[arber333]

I took TE HVA280 Key A 2 pole connector with wires from my broken Volvo/Eltek charger. It is the correct key and directly connects to the charger DC side. I also found a kit YHVA280-2PHI-4MM-A here:
https://eu.mouser.com/ProductDetail/TE- ... fbfA%3D%3D
https://eu.mouser.com/datasheet/2/418/7 ... 026828.pdf

For AC side i ordered Aptive HES 13879048 connector and female pins 13783291 from Mouser. That was available. I will report back when i can try them on.

[arber333]

Testing success!
I couldnt let it rest and i connected charger AC lines via some fastons. I connected HV to my test battery and LV control connector to 12V and my PWM pulse generator. I got good steady 9A of charging at 366Vdc! Control is really simple 100Hz with duty 25% to 90% varying current at an unknown rate.
After 90% duty charger drops out and if i lower it below 90% i get 9A again.
Charger has rather low thermal mass and can heat up quickly so any testing at full power is limited if not liquid cooled.
Later on i will add another module to my battery to test if this charger works with more than 400Vdc.
https://leafdriveblog.wordpress.com/202 ... 2-charger/

[vwbrady]

awesome news! I went ahead and ordered the HV and comm connector parts this morning.

What did you use for a PWM generator? I'm excited to hear more about this!

[arber333]

awesome news! I went ahead and ordered the HV and comm connector parts this morning.

What did you use for a PWM generator? I'm excited to hear more about this!

What i use in my car is Arduino DUE module and my own shield with inputs and outputs suitable to CAN bus, relay and PWM connection. DUE uses PWM pins which you can drive using analogwrite() function and make it variable .
Here is my DUE shield with history: https://github.com/arber333/Arduino-Due-CAN-shield

In my blog to prove it works i used my trusty Feeltech Fy3200 signal generator off of Ebay...

[vwbrady]

Sorry if this is a dumb question, but does your shield utilize the DUE PWM pins to then generate 12v PWM? My understanding is that the arduino PWM pins only do 3 or 5v. Again, this could be a ridiculous question cause by my ignorance of Arduino and PWM generation.

[arber333]

Sorry if this is a dumb question, but does your shield utilize the DUE PWM pins to then generate 12v PWM? My understanding is that the arduino PWM pins only do 3 or 5v. Again, this could be a ridiculous question cause by my ignorance of Arduino and PWM generation.

You are correct and i use mosfet transistor module to switch 12V. I use DUE to command this module with 3V3 signal.
I havent tested it with charger but DCDC will work with 5V PWM signal.

[vwbrady]

that's exactly what i thought would need to happen! im a little surprised i figured that out.
Any chance you'd like to sell me one of your shields, if you have any unused?

thanks, Arber!

[arber333]

YA! I got Aptive HES 13879048 connector and female pins 13783291 from Mouser. Crimp pins are perfect fit.
13879048 turned to be 2 + 2 connector. 2 pins being power pins and 2 signal pins. For my use 2 pins had their cavity blocked.
Connector still fits though. I made short work of the stops and drilled out the plastic. I was a little afraid pins wouldnt fit, but it works perfectly. There is also a rubber seal inside which will protect connector from moisture and dust.

I am not sure 13879050 would be any different...

EDIT: I also tested charger can work with PWM from 90Hz to 108Hz.
EDIT2: I tested charger with 180Vdc battery and it started at 9A for a few seconds and then stopped charging. Not surprising...

[arber333]

that's exactly what i thought would need to happen! im a little surprised i figured that out.
Any chance you'd like to sell me one of your shields, if you have any unused?

thanks, Arber!

I think i have one V4 board left. Send me PM.

[900]

What i use in my car is Arduino DUE module and my own shield with inputs and outputs suitable to CAN bus, relay and PWM connection. DUE uses PWM pins which you can drive using analogwrite() function and make it variable .
Here is my DUE shield with history: https://github.com/arber333/Arduino-Due-CAN-shield

In my blog to prove it works i used my trusty Feeltech Fy3200 signal generator off of Ebay...

Oh wow I like the charger and the DUE shield! A lot neater than just using separate CAN modules on the DUE which you can't attach neatly. What are you using for the schottky diode on your shield? Is the mosfet transistor module for 12v is attached separately? Cheers

[arber333]

Oh wow I like the charger and the DUE shield! A lot neater than just using separate CAN modules on the DUE which you can't attach neatly. What are you using for the schottky diode on your shield? Is the mosfet transistor module for 12v is attached separately? Cheers

Yes i designed the board to use any CAN or PWM control charger. Diode is there for the time a moron(me) connects 12V in reverse. And it is just a power diode. Its voltage drop keeps the DUE 5V regulator safe, since a car battery is more than 12V. I included a regulator in case i needed it...
If you use one outlander charger you can connect cp directly. But for PWM you need add on module. You choose your mosfet or darlington. You could also make an add on mosfet board on top of my board and connect it via vertical pins.

[900]

Diode is there for the time a moron(me) connects 12V in reverse.

Ha it happens for everyone sometimes so better to safeguard against such incidents of course! Do the specs of that schottky matter or any does the job?

And it is just a power diode. Its voltage drop keeps the DUE 5V regulator safe, since a car battery is more than 12V. I included a regulator in case i needed it...

Does that mean you are also powering DUE from your shield now? Which regulator is that? 5v?

If you use one outlander charger you can connect cp directly. But for PWM you need add on module. You choose your mosfet or darlington. You could also make an add on mosfet board on top of my board and connect it via vertical pins.

That's a cool idea! Would be even cooler to incorporate that into the shield if space allows it but maybe an add on would be easier.

[arber333]

That's a cool idea! Would be even cooler to incorporate that into the shield if space allows it but maybe an add on would be easier.

Well you have UL2008 chip onboard to handle various relays. Its outputs are configured to sink 12V directly. So you really just need to add a pullup to 12V to have a positive signal. PWM however is on 3V3 level and you need to have an amplifier. I decided to add another board since it is not often you need PWM. Maybe in V5 i will add couple of mosfets just for completeness...

[900]

Testing success!
I couldnt let it rest and i connected charger AC lines via some fastons. I connected HV to my test battery and LV control connector to 12V and my PWM pulse generator. I got good steady 9A of charging at 366Vdc! Control is really simple 100Hz with duty 25% to 90% varying current at an unknown rate.
After 90% duty charger drops out and if i lower it below 90% i get 9A again.
Charger has rather low thermal mass and can heat up quickly so any testing at full power is limited if not liquid cooled.
Later on i will add another module to my battery to test if this charger works with more than 400Vdc.
https://leafdriveblog.wordpress.com/202 ... 2-charger/

Hi, how does this charger handles end of charge constant voltage mode? What would be the best way to control it?

[arber333]

Hi, how does this charger handles end of charge constant voltage mode? What would be the best way to control it?

I am thinking of using isa shunt or similar CAN voltage reporting to asses voltage and command gradual PWM reduction until desired voltage is reached. I will use my Arduino due shield to for control. I also use Eltek charger which is sending reports on pack voltage. You can also use that.

[900]

Yes i designed the board to use any CAN or PWM control charger. Diode is there for the time a moron(me) connects 12V in reverse. And it is just a power diode. Its voltage drop keeps the DUE 5V regulator safe, since a car battery is more than 12V. I included a regulator in case i needed it...

Hi, trying to choose a power diode (D6) for your shield. Are you powering the Due through your shield entirely from 12 V? Do you have any idea what the current consumption of the shield and Due might be? Also what forward voltage have you chosen and what voltage drop? I've currently got a simple 1N4007 at home but it may be too weak as only rated for 1 A? Thanks

[arber333]

Yes i designed the board to use any CAN or PWM control charger. Diode is there for the time a moron(me) connects 12V in reverse. And it is just a power diode. Its voltage drop keeps the DUE 5V regulator safe, since a car battery is more than 12V. I included a regulator in case i needed it...

Hi, trying to choose a power diode (D6) for your shield. Are you powering the Due through your shield entirely from 12 V? Do you have any idea what the current consumption of the shield and Due might be? Also what forward voltage have you chosen and what voltage drop? I've currently got a simple 1N4007 at home but it may be too weak as only rated for 1 A? Thanks

Whatever 3A or 5A diode will do. I am just using it to be foolproof against idiots like me who want to connect power in reverse .
Added benefit is diode drops the voltage a bit so arduino regulator doesnt see too high voltage.

[900]

Whatever 3A or 5A diode will do. I am just using it to be foolproof against idiots like me who want to connect power in reverse .
Added benefit is diode drops the voltage a bit so arduino regulator doesnt see too high voltage.

Very helpful thanks! I've populated your shield programmed the Due and was trying to get some CAN communication going. Sadly I get nothing. I checked the CAN transciever pinout on your shield and it is correct. However when I checked the voltage on CAN transciever GND and VCC pins I get 3.2 v on first transciever and only 0.85 v on the second (near C5). When I try to trace the voltage back I get 2.2 v on C6. I've populated pretty much all the shield according to BOM except C3, C2, Q6, D1 and relays as I only need the CAN to work at the moment. Do you have any ideas what might be wrong? I'm powering Due through its own usb port right now. What is jumper 3 for? Thanks

EDIT: After further diging there appears to be no trace to supply 3.3 v to the U4 CAN transcievers VCC pin. How is it meant to be supplied? There is no continuity between U3 and U4 VCC pins. This is shield V4.

[TonyV]

I just pick up a charger from a 2018 Chevy Volt.
It look's like GM made a change in the design.
They separated the DC to DC converter from the Hi Voltage charger.
Part number for Charger = 24286781
Part number for DC to DC converter = 24284603

Would anyone know the wiring diagram and if this one works the same way?


Thanks,

[arber333]

Very helpful thanks! I've populated your shield programmed the Due and was trying to get some CAN communication going. Sadly I get nothing. I checked the CAN transciever pinout on your shield and it is correct. However when I checked the voltage on CAN transciever GND and VCC pins I get 3.2 v on first transciever and only 0.85 v on the second (near C5). When I try to trace the voltage back I get 2.2 v on C6. I've populated pretty much all the shield according to BOM except C3, C2, Q6, D1 and relays as I only need the CAN to work at the moment. Do you have any ideas what might be wrong? I'm powering Due through its own usb port right now. What is jumper 3 for? Thanks

EDIT: After further diging there appears to be no trace to supply 3.3 v to the U4 CAN transcievers VCC pin. How is it meant to be supplied? There is no continuity between U3 and U4 VCC pins. This is shield V4.

You are correct! U3 has +3V3 on pin5 routed through via under chip. Please check if there is a connection. If not you need to establish the connection to the underside.
For U4 however it seems i have missed that connection completely. On the board underside is +3V3 layer. The best way to resolve this is to drill a 1mm hole near the pin5 of U4 and then countersink hole with 3mm drill from the top to remove top layer which is GND. Then on the underside scrape some protection and solder a wire, rout it through hole and solder it to pin5 on the other side. After everything is finished i use my daughters nail polish (dark violet) to protect the mess.

JP3 is setup to connect (or not) the 120R resistor for termination. If you connect 2 jumpers you effectively become the last CAN device online.

There is another thing/error. I noticed U4 pin1 is connected to D51 which is incorrect. CANtx1 pin should be connected to D53.
Again the best way would be to chop off the connecting pin under D53 and connect a bridge from D53 to D51. That way you get fuction of CAN0 and CAN1.

Sorry for the error. I will correct the design and publish rev4.1 ASAP.

[arber333]

I just pick up a charger from a 2018 Chevy Volt.
It look's like GM made a change in the design.
They separated the DC to DC converter from the Hi Voltage charger.
Part number for Charger = 24286781
Part number for DC to DC converter = 24284603

Would anyone know the wiring diagram and if this one works the same way?


Thanks,

This is actualy the same Volt gen2 charger. There is some variation with P/Ns, but it is the same device.
I also have described my test here:
https://leafdriveblog.wordpress.com/202 ... 2-charger/

DCDC converter is also the same. Its function is described here...
viewtopic.php?f=25&t=978
https://leafdriveblog.wordpress.com/202 ... gen2-dcdc/

[900]

Sorry for the error. I will correct the design and publish rev4.1 ASAP.

Thanks Arber! The pin 1 on U4 is connected to pin 53 on my shield so it seems correct? So if you could change the Vcc to U4 issue that would be great. I would also suggest to increase the pitch of CAN1 terminal. At the moment it is 2.54 mm there are not many sturdy enough terminals with that pitch. If you could incorporate some transistors for doubling chargers that would be fantastic. I'm happy to order some updated shields and send to you a batch for testing if you like. Overall I like the design - much better than connecting separate small extension boards to the Due - much more sturdy and compact.

Regarding the Vcc to U4 issue I just routed a small wire between C4 & C5 bottom pads would that be alright or could cause some issues? And I got the CAN communication working on both transcievers. I wonder what C6 is for? Doesn't look like you are populating it on your shields? Also are R20 & R24 termination resistors for CAN1? Thanks

[arber333]

Sorry for the error. I will correct the design and publish rev4.1 ASAP.

Thanks Arber! The pin 1 on U4 is connected to pin 53 on my shield so it seems correct? So if you could change the Vcc to U4 issue that would be great. I would also suggest to increase the pitch of CAN1 terminal. At the moment it is 2.54 mm there are not many sturdy enough terminals with that pitch. If you could incorporate some transistors for doubling chargers that would be fantastic. I'm happy to order some updated shields and send to you a batch for testing if you like. Overall I like the design - much better than connecting separate small extension boards to the Due - much more sturdy and compact.

Regarding the Vcc to U4 issue I just routed a small wire between C4 & C5 bottom pads would that be alright or could cause some issues? And I got the CAN communication working on both transcievers. I wonder what C6 is for? Doesn't look like you are populating it on your shields? Also are R20 & R24 termination resistors for CAN1? Thanks

Ok, i have corrected the issue with power supply. That is a good mod with C4 to C5.
C6 is decoupling cap of some nF capacitance. I took it from Damiens design .
I agree, CAN1 connector is a little smallish. I am using KF2510-2P 2.54mm connectors which are locking and cannot be reversed. It can accept wires up to 0.5mm2 so you neet to teke this into account. I can add B2P-VH header and it will hold 3.96mm pitch connectors with wires up to 1mm2.

So by transistors you mean NPN mosfet on the PWM pins? I could do that and add possible 12V line so you could simply add a wire and command PWM to charger or DCDC.

Since i use a diode for some time now i am thinking of eliminating 12V regulator. It seems all regulators have a bottom limit at 14V and if your battery goes below than some brown outs may occur. Pleaase let me know if someone has other suggestion.
Also i suggest we move this discussion here: viewtopic.php?f=17&t=1148

I will update design with rev. 4.1 and post it on github.

EDIT: I am also thinking of making another shield to be put on top of the first one which would add LIN bus or SW CAN functionality. But would sacrifice CAN1 for that. It could add additional digital inputs and outputs to be used. Any ideas?