openinverter forum

I've looked high and low but I cant find anywhere the pin layout for the GEN 2 battery charger control plug.
Can someone tell me where Pin 1 is? Or better yet a link to a pinout somewhere would be awesome.
I checked amber's blog and he describes the pins but I really could use the pin layout.
Thanks

Ok, i am away from PC now and cant do much. But observe in my blog how i used all black wires with numbers and single green/yellow wire. Well that is P2 GND (black wire in your photo) wire. P1 is not populated and then you can count wires from there. You only really need 4 wires P2, P4, P9 and P11.
I think you can also download molex connector datasheet to see pinout distribution.

I will draw a schematic when i am home...

Can the Gen2 Charger be controlled by CanBus?

TonyV wrote: ↑Wed Jul 28, 2021 7:40 am Can the Gen2 Charger be controlled by CanBus?

No, gen2 charger needs PWM duty command to start and it reports with PWM duty on dc voltage and power.

Is this the correct unit-its labelled as 3.3kw

https://www.ebay.co.uk/itm/273706742983 ... 1438.l2649

zippy500 wrote: ↑Wed Jul 28, 2021 7:16 pm Is this the correct unit-its labelled as 3.3kw

https://www.ebay.co.uk/itm/273706742983 ... 1438.l2649

Yes it is Volt gen2 charger. The gen1 was 3.3kW but it also had 250W 12V charger inside. So technicaly it was close to 3.6kW all in all.
I think 3.6kWh applies if you consider 9.3A at 380Vdc which i got from it on last try!

DANG! I tried to charge a 104S battery and Gen2 charger just wont work over 400Vdc.
Whereas when i tried with 96S battery it started to charge immediately.
That is a shame!

Anyone has spare connectors for this charger?
Trying my best to find them but not on stock or per 50 etc

EV_Builder wrote: ↑Mon Oct 11, 2021 9:46 am Anyone has spare connectors for this charger?
Trying my best to find them but not on stock or per 50 etc

At the time i was ordering my set they were relatively good priced. Now they are unobtanium. I sold my charger but i was preparing to remove connectors and make alternative flanges with grommets for cables. Maybe model for 3d primter similar to outlander motor?
I think it would be easier to make new connection and seal it with sika or similar sealant.

Im interested in one of these will it work for 108s Lifepo4 pack 404vdc max ?? Seems like mouser has no stock on hv connectors

No they dont work above 400Vdc.

So what is maximum actual voltage ?

thetdiguy wrote: ↑Sat Nov 20, 2021 5:38 pm So what is maximum actual voltage ?

I tried 378, 388V and 392V.
I also tried 410V and it would only start at 9A and shutdown after 1s.

So you confirmed up to 392 ?

thetdiguy wrote: ↑Sat Nov 20, 2021 9:33 pm So you confirmed up to 392 ?

Well yes i got my battery up to 392 using Volt gen2 charger.

arber333 wrote: ↑Sat Nov 20, 2021 6:23 pm

thetdiguy wrote: ↑Sat Nov 20, 2021 5:38 pm So what is maximum actual voltage ?

I tried 378, 388V and 392V.
I also tried 410V and it would only start at 9A and shutdown after 1s.

Could the problem just be that you are exceeding the power limit of the unit? 410V and 9A would be 3690W. Maybe try 410V and 8A?
At 95% eff and 240VAC you would get over 16A input current which above the limit there too. The attached sheet shows the charger should go to 430V output.

NutsnVolts wrote: ↑Wed Dec 15, 2021 2:13 pm Could the problem just be that you are exceeding the power limit of the unit? 410V and 9A would be 3690W. Maybe try 410V and 8A?
At 95% eff and 240VAC you would get over 16A input current which above the limit there too. The attached sheet shows the charger should go to 430V output.

07873390.pdf

Hm... interesting. I have tried varying frequency from 90Hz to 110Hz and tried varying duty from 75% to 96%. I could go up to 90% where charger stopped responding at nominal voltage of 375Vdc and 9.1A. When i added another battery module to get 406Vdc and tried to charge i got 9A for a second and then charger dropped out.
I found controling the charger really more demanding than Eltek chargers which use CAN system and have implemented own protection mechanisms.

Maybe someone would be willing to test with more than 400Vdc and PWM command at lower than 70% duty?

just got my second gen Charger/Converter set on eBay, sharing the charger listing (items were purchased separately) to show folks what they go for as of the current date, brace yourselves for death by a 1,000 questions, ha ha

Part Number: 24281923
Supersession(s): 24277705

Part Number: 24291446
Supersession(s): 24275451; 24286781
https://www.gmpartsmog.com/p/75741768/24291446.html

this shows where Chevy Volt Gen 2 (2016-2019) charger aka the On Board Charging Module or OBCM is housed inside the trunk of the vehicle in case you find one in the wild and want to lift it

I have also been collecting these on eBay for cheap. Have 3 chargers and 2 DCDC right now. They're just so compact!

I designed a bracket for them to be mounted together. LMK if anyone is interested.

So i came across a new and cheap Chevy Volt charge inlet assembly on ebay and decided to grab it, if only for the charger side connector. Interestingly it also includes the J1772 pilot and proximity connections. I'm now wondering if this charger will handle EVSE connectivity on it's own instead of running something like an AVC2.

Has anyone looked into this? I may be able to test this in the near future when i get my PWM generator wired up.

vwbrady wrote: ↑Thu Apr 07, 2022 3:53 pm So i came across a new and cheap Chevy Volt charge inlet assembly on ebay and decided to grab it, if only for the charger side connector. Interestingly it also includes the J1772 pilot and proximity connections. I'm now wondering if this charger will handle EVSE connectivity on it's own instead of running something like an AVC2.

Has anyone looked into this? I may be able to test this in the near future when i get my PWM generator wired up.

No. This charger will start under conditions
1. DC is present
2. AC is present
3. 100Hz PWM on pin4

Cp is used on the separate controler (HPCM2?) which in turn sets PWM signal for the charger to follow.

Gotcha, so it's a pass through. Makes sense tbh. Looks like I'll be continuing with the ACV2

someone actually asked how much this thing weighs, so Greg to the rescue

Hey, couple questions.
-Do I need a HV battery hooked up in order for charging to start? Was just going to stick some multimeter probes on the end of the cable.
-Is there any indication that the charger is on? I’m giving it 12v on pins 9 and 2 and it’s not drawing any current. Also, I don’t see any lights on inside or hear any noise.
-Is the output voltage a constant 400v when it’s working? I see some posts claiming to charge at 360v and I didnt think you could control that.

TIA
Luke