[DRIVING] VW Touran powered by Nissan Leaf  [FINISHED]

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Re: VW Touran powered by Nissan Leaf

Post by arber333 »

johu wrote: Thu Oct 28, 2021 7:36 pm I have a weird setup. The transmission is in a classic rubber bushing so it can only move that far. The motor mount rests on rubber but can swing freely. And then there's the torque arm that should take most load on accelerating and regen.
I would not trust aluminum. Constant torquing will make it brittle and can create a crack near the bolt hole. There is the thinnest part towards outside
I would suggest inox steel or equivalent good tensile strong steel...
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Re: VW Touran powered by Nissan Leaf

Post by johu »

Ok, the Chinese inverter finally gave up. Probably the inductor shorted out because all the enamel is gone and then the transistor blew. As a "nice" little side effect that took out my little DC-DC converter that delivers logic supply and that then took out my entire ULN2003 array, shorting all channels to GND. Guess what happened to the positive contactor upon next power-on? Yes it switched on without precharging and is now welded.
Also my vacuum pump never turned on, that has one inversion stage after the ULN. So had to drive home 40 km with brute force braking :roll:

As another little bonus I now know what an AC rated fuse looks like when it interrupts DC: it melts the fuse holder and spreads little glass and metal balls all over the place.

Does anyone have those Panasonic Nissan Leaf contactors collecting dust?
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Re: VW Touran powered by Nissan Leaf

Post by Boxster EV »

I have several Panasonic contactors left over from a gen 1 Chevy volt pack if you need them.
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Re: VW Touran powered by Nissan Leaf

Post by johu »

Boxster EV wrote: Thu Nov 11, 2021 1:14 pm I have several Panasonic contactors left over from a gen 1 Chevy volt pack if you need them.
Cool, is it these ones? viewtopic.php?f=4&t=1968 (Panasonic AEV6505A)
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Re: VW Touran powered by Nissan Leaf

Post by Boxster EV »

johu wrote: Thu Nov 11, 2021 3:02 pm
Boxster EV wrote: Thu Nov 11, 2021 1:14 pm I have several Panasonic contactors left over from a gen 1 Chevy volt pack if you need them.
Cool, is it these ones? viewtopic.php?f=4&t=1968 (Panasonic AEV6505A)
Yes I think they are the same. Would need to check p/n when back home.
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Re: VW Touran powered by Nissan Leaf

Post by ZooKeeper »

johu wrote: Thu Nov 11, 2021 12:22 pm As another little bonus I now know what an AC rated fuse looks like when it interrupts DC: it melts the fuse holder and spreads little glass and metal balls all over the place.
So there is a test Damien has not done and published????
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Re: VW Touran powered by Nissan Leaf

Post by Boxster EV »

Boxster EV wrote: Thu Nov 11, 2021 3:34 pm
johu wrote: Thu Nov 11, 2021 3:02 pm
Boxster EV wrote: Thu Nov 11, 2021 1:14 pm I have several Panasonic contactors left over from a gen 1 Chevy volt pack if you need them.
Cool, is it these ones? viewtopic.php?f=4&t=1968 (Panasonic AEV6505A)
Yes I think they are the same. Would need to check p/n when back home.
D515791A-2D4F-4FB1-B3CA-646911F68998.jpeg
Any good?
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Re: VW Touran powered by Nissan Leaf

Post by johu »

Boxster EV wrote: Fri Nov 12, 2021 8:49 am Any good?
Thanks but wrong form factor, they seem to mount standing up
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Re: VW Touran powered by Nissan Leaf

Post by chrskly »

johu wrote: Sat Nov 13, 2021 10:26 am
Boxster EV wrote: Fri Nov 12, 2021 8:49 am Any good?
Thanks but wrong form factor, they seem to mount standing up
I have these two spare. Pulled from a BMW s-box. They’re yours if you want them.
41C65D2B-3E52-41D4-A97D-FF09B6521583.jpeg
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Re: VW Touran powered by Nissan Leaf

Post by johu »

chrskly wrote: Sat Nov 13, 2021 10:45 am I have these two spare. Pulled from a BMW s-box. They’re yours if you want them.
That comes closer, worth a try
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Re: VW Touran powered by Nissan Leaf

Post by MattsAwesomeStuff »

johu wrote: Thu Nov 11, 2021 12:22 pm - Ok, the Chinese inverter finally gave up.
- took out my little DC-DC converter that delivers logic supply
- took out my entire ULN2003 array, shorting all channels to GND
- positive contactor upon next power-on? is now welded.
- vacuum pump never turned on
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Re: VW Touran powered by Nissan Leaf

Post by SKB123 »

Hi

I cant upload image but number on mine is AEV6505A
Should know better - Learning, one f@#$ up at a time :D
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Re: VW Touran powered by Nissan Leaf

Post by johu »

I just received the AEV14012 contactors from chrskly today (thanks very much :) ). It largely seems to be the same design. The mounting holes are smaller but at the same location. The connector for the coil is identical. The resistance is a bit less, 25 vs. 31 ohms.

Unfortunately it doesn't click right into Nissans assembly because the back side is all flat. Also the front bracket of the "Nissan" variant is designed to hold a 90° busbar, but that could also be fitted to the 14012 just with less plastic support.

Now that I found I can just hit these things with a hammer I might resort to that for now.
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Re: VW Touran powered by Nissan Leaf

Post by janosch »

johu wrote: Mon Nov 29, 2021 9:39 am ... Now that I found I can just hit these things with a hammer I might resort to that for now...
Does that un-stick them? I got a hammer here that is waiting for action.
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Re: VW Touran powered by Nissan Leaf

Post by johu »

janosch wrote: Tue Nov 30, 2021 1:59 pm Does that un-stick them? I got a hammer here that is waiting for action.
Apparently, yes. Infinite resistance when coil not powered, no resistance when powered. Remains the question whether the contact area is diminished by the welding causing excess heat losses.
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Re: VW Touran powered by Nissan Leaf

Post by johu »

Worked on improving the car today, 2 steps forward, 1 back...

So first I searched the CAN bus for the "Econ" button that is usually meant for switching off the A/C compressor. And indeed, on message 0x5E0 bit 1 turns off when Econ is pressed on turns on with Econ mode disabled. Conveniently it also turns off when shutting off Climatronic completely. So the perfect bit to use for turning the water heater on and off. Job done.

So next I set out to be able to run the cabin heater while charging. This mostly means switching on the DC relay after precharging and then running DC-DC converter and heater. So I simply compare the BMS voltage and the inverter voltage and once they match within 10V I turn on the contactor. All works. Once at least.

If you turn off ignition, the relays loose their 12V supply and drop, despite the VCU telling it to turn on. Now guess what happens if you turn on ignition once again.... They all close immediately. So another set of Panasonic relays welded :(

Anyone have another set of AEV6505A?
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Re: VW Touran powered by Nissan Leaf

Post by Bratitude »

johu wrote: Fri Dec 31, 2021 1:39 pm Worked on improving the car today, 2 steps forward, 1 back...


Anyone have another set of AEV6505A?
https://www.ebay.ca/itm/294535724412?ha ... SwTdNhix37

in canada, but he'll sell them for 100$ cad.
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Re: VW Touran powered by Nissan Leaf

Post by johu »

So I just hit my other welded contactors with the hammer some more and they are free! Measured 4 mV drop at 16A so the contact area doesn't seem to be destroyed. Would dissipate 22W @ 300A.
If anyone has a fresh set, can they do the same measurement? I strictly divided the test current from the voltmeter leads to only measure the drop across the terminals.
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Re: VW Touran powered by Nissan Leaf

Post by johu »

Update: the welded contactors in the car freed themselves! I just got in there with a meter today to find 0V with the car off. Thanks very much :D
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Re: VW Touran powered by Nissan Leaf

Post by EV_Builder »

@Johu i missed this; are you still in need of stuff? Post a picture of what you need here.
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see http://www.wdrautomatisering.nl for bespoke BMS modules.
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Re: VW Touran powered by Nissan Leaf

Post by johu »

Thanks, all is well. These are the contactors in question: https://openinverter.org/forum/viewtopi ... 438#p34438
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Re: VW Touran powered by Nissan Leaf

Post by johu »

Haven't mentioned it yet, I replaced the guts of the Chinese inverter with a stronger version without the 12->450V transformer stage
https://de.aliexpress.com/item/40012097 ... 4c4dijPkuY

The cooling makes much more sense now, the fan always runs and blows via the fins. All works flawlessly now.
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Re: VW Touran powered by Nissan Leaf

Post by zippy500 »

Output Voltage: AC220V

What do you use this for ?
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Re: VW Touran powered by Nissan Leaf

Post by johu »

So far only for the 220V heater. In summer for powering beer dispenser, fridge, stereo. And maybe for some power tools.
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Re: VW Touran powered by Nissan Leaf

Post by johu »

Some combined GT86 and Touran action this week. I drove to Zapatero in Ulm (400km away) on Sunday night. Again, the trip didn't go quite as planned. Driving was all smooth but as always, charging was not:
1st stop: couldn't even grab the CHAdeMO connector, it was locked in the EVSE. Some high power charge was seemingly available but it turned out it couldn't serve CHAdeMO and CCS at the same time. Thought only triple chargers had that limitation. So I drove on to the
2nd stop: all good, charged to 90% as I did a phone call while charging
3rd stop: used the time for some lunch, perfect!
4th stop: charging didn't start. Called support, but all they ever do is reboot the charger. Which didn't cure anything. So support rebooted it again which resulted in the screen turning black permanently. Bugger it, still had 25% left, so drove to the next town and charged one hour on an AC EVSE with Prius charger. Popped the overload protection a few times while searching for peak power but was always able to restart
6th stop: Another Fastned, worked flawlessly

I no longer try to deplete the battery as much as possible, because a) you get stranded very quickly b) prolonged charging at 50 kW heats it up so much that you get reduced speed at the next stop anyway.

Finally arrived at Philips workshop at 11 at night. An enormous storm went by over night, making it hard to sleep (The workshop has a sort of living room upstairs).

Next morning Philip arrived and after some breakfast we both set to work. I grabbed his new GT86 VCU and did some pin hunting, bug fixing and CAN mapping. He worked for hours and hours drilling, cutting and bending all the aluminium that he'd ordered beforehand.
The result of both was very satisfying, Touran now has 20mm of extra ground clearance, a super nice looking battery box that even features a little door for pulling the service disconnect.

We finally called it a day at 11 nighttime, again.

Drive home was quite good, this time it was merely driver and car that failed. I failed to enter A8 in the correct direction and added 25 extra kilometers to the trip to correct for that. Nissans BMS started playing up at the last charge stop. Normally it starts reducing power when the hottest of the 3 sensors hits 53°C. Now, even before I charged I got at 50 kW discharge limit and some equally ridiculous charge limit, despite hottest temp being 45°C. I decided to override it with my little cheat parameter. When setting off I had a power limit of 25 kW! Manually upped it to 50 kW to make it up "Kasseler Berge" (some of the steepest highway stretches in Germany).

Even after parking the car for 30 minutes there was still a 100 kW power limit, reason "Capacity Drop". What??

To round off the day, when I plugged in my 3-phase charger the houses GFCI tripped, as soon as the main relay closed. An alarming smell came from underneath the car. I thought BMS. But no, it was my little CAN repeater and the CAN transceiver in my VCU that had given up the ghost. Replaced the transceiver to at least render the car drivable again. Now just need to repair the repeater and find out what the hell happened before attempting to charge again.

I already noticed the last couple of days that the GFCI would sometimes trip when charging. Turning around the Schuko plug (it has no polarity) "fixed" it, but there is definitely something wrong. I suspect it's the 3D-printed CHAdeMO connector that has seen a bit too much rain. I can't find an isolation problem in the car itself.
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