Chevy Volt Gen1 Charger

[bobbyj_408]

I tried to find the three pin last year but everywhere I looked they were NLA.

If you get a two pin one you could adapt it to fit, as the outer parts are the same. Think I might have a couple in the garage.

Dang... I did notice your post from last year... how did you get around it? Find a wiring harness?

Ahh, Hmmm, I suppose I could try adapting a two pin. Hmmm, worth a shot I suppose!

If you have an extra 3 pin lying around, please let me know!

[bobbyj_408]

Anyone know how I can bench test the charger? I have a SimpBMS board, so I figure I can control the charger that way, but what kind of load should I connect it to? Ideally I would like to test it on something before connecting it to the main battery. Thoughts?

[arber333]

Anyone know how I can bench test the charger? I have a SimpBMS board, so I figure I can control the charger that way, but what kind of load should I connect it to? Ideally I would like to test it on something before connecting it to the main battery. Thoughts?

There is allready a link to my blog at the start of this thread. I had to test Gen1 charger as well and i simply connected two light bulbs inline on the HV output and 12V light bulb on the LV output. To start you need to connect 12V pins and send a priming telegram first and keep sending it at 30ms intervals, only then you can send the control signal at slower 500ms.
https://leafdriveblog.wordpress.com/201 ... a-charger/

[bobbyj_408]

Man, having a pretty tough time here. I connected the charger input's L1 and N to a 110v outlet (leaving L2 disconnected because I dont have a split phase supply), connected the 12v and CAN lines to my CAN bus according to the link below, programmed a Teensy 4 to send the correct messages (30ms heartbeat and 500ms charge signal, connected the output of the charger to 4 light bulbs in series, tuned it all on... and nothing... Below are some CAN captures from a second Teensy that I have monitoring the bus. I think this looks right.

Any ideas?? I really need the help.

https://leafdriveblog.wordpress.com/201 ... a-charger/

Code: Select all

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2952261 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2952291 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2952321 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2952351 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2952381 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2952411 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2952441 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2952471 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2952501 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2952531 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2952561 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2952591 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 4 EXT: 0 TS: 2952592 ID: 304 Buffer: 40 A0 3 20 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2952621 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2952651 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2952681 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2952711 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2952741 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2952771 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2952801 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2952831 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2952861 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2952891 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2952921 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2952951 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2952981 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2953011 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2953041 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2953071 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 4 EXT: 0 TS: 2953092 ID: 304 Buffer: 40 A0 3 20 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2953101 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2953131 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2953161 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2953191 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2953221 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2953251 ID: 30E Buffer: 2 

MB 99  OVERRUN: 0  LEN: 1 EXT: 0 TS: 2953281 ID: 30E Buffer: 2 

[arber333]

Man, having a pretty tough time here.

Well, Volt gen1 charger has 2 CAN bus outputs, but it only uses one of them, pins 2, 3.
You need to provide pins 1, 6 and 7 with 12V. Pin 7 is interlock and nothing works without it powered. Pin 6 is 12V from Enable relay. Pin 1 is charger 12V supply. GND is connected on the Aux output side, but there you need to have 12V battery connected otherwise it wont work!
The moment you transmitt CAN primer msg 030E 03 you should hear relay turn on inside charger. Then you provide CAN control msg 0304 40 C8 03 34 and you should get up to 10A 410V.

[bobbyj_408]

Well, Volt gen1 charger has 2 CAN bus outputs, but it only uses one of them, pins 2, 3.
You need to provide pins 1, 6 and 7 with 12V. Pin 7 is interlock and nothing works without it powered. Pin 6 is 12V from Enable relay. Pin 1 is charger 12V supply. GND is connected on the Aux output side, but there you need to have 12V battery connected otherwise it wont work!
The moment you transmitt CAN primer msg 030E 03 you should hear relay turn on inside charger. Then you provide CAN control msg 0304 40 C8 03 34 and you should get up to 10A 410V.

Oh man! Well sounds like this could be one source of error. I was connecting the 12V GND to the frame (I assumed a chassis ground set up). Ok, I'll give that a shot.

[bobbyj_408]

Oh man! Well sounds like this could be one source of error. I was connecting the 12V GND to the frame (I assumed a chassis ground set up). Ok, I'll give that a shot.

Hmmm, that didnt work. I connected pins 1, 6, 7 to 12V, the aux to 12V battery, L1 and N to 110V wall outlet, and nothing. Could it be that I need to connect both L1 and L2?


Also, could it be because of the relatively low voltage CAN signal? The teensy is sending CAN via the transducer, and the logic level is at 3.3V.

[P.S.Mangelsdorf]

Does anyone have the color coding of the 12V harness?

The one for my charger was cut rather than unplugged.

[arber333]

Does anyone have the color coding of the 12V harness?

The one for my charger was cut rather than unplugged.

Here you go. Courtesy of Jack Rickard...

[P.S.Mangelsdorf]

Does anyone have the color coding of the 12V harness?

The one for my charger was cut rather than unplugged.

Here you go. Courtesy of Jack Rickard...

Thank you!

[P.S.Mangelsdorf]

So I purchased the Chevy Volt charger, but now I need the Delphi connectors. The 2 pin connector seems to be Delphi / APTIV P/N 33107347 , but I cant find info on the 3 pin connector. Any help there?

Just an FYI: It appears Delphi/Aptiv has made some tweaks to this part #, so some trimming is required to get it to mate with the charger. (at least the charger I have)

[Gregski]

I am late to the party as per usual but would like to contribute what I can to this thread instead of rolling my own

absent an actual Chevy Volt in my possession I resorted to an old resource AllData.com an online user/service manual portal, and purchases a 1 month subscription for the first gen Volt for $20 bucks

I had questions:

1. where is the onboard charger even located?

2. what does the charge port connect to, does it plug in directly to the charger?

[Gregski]

and here are the labeled key components

[Gregski]

alright I believe I have identified the actual part number for the Charger to Battery gen 1 cable part #22889574

Supersession(s): 22744388; 22827024

and as seen in the wild

[Gregski]

so I swung by a local all Chevy parts wrecker today in my town and they said they had one first gen Chevy Volt a 2014 model and they would let me go and look at it with them and tell them what parts I needed that were still on it, they were also kind enough to allow me to take some pics so now I can share with confidence the location of said components

[Gregski]

so I bought the charge port and its orange tail, please be advised, unlike all the other orange "two nostril" cables, this one has three nostrils!

Drive Motor Battery Pack Charging Port Assembly (2011-2013)
Part Number: 23281030
Supersession(s): 22759324; 22822889; 22975305; 23453436


long orange cable from charge port to charger part # 20972413 (no other superseded numbers)

CT11100_12.png (25.58 KiB) Viewed 14294 times

#3 in the pic below:

[Gregski]

so I am happy to report I just scored a Chevy Volt gen 1 (2011-2015) onboard battery charger for $280 at a local wrecker, so no shipping costs

and I must say the father and son Armenian duo at the wrecker (in Rancho Cordova, California) that sold it to me, are the nicest salt of the earth folks I ever ranned into - Thank You So Much

[Gregski]

and here is the driveway wiring diagram

[Gregski]

oh the fun rages on, so I want to get the OEM charger cable for the first gen Chevy Volt onboard charger and so I went looking for the part number and found this: (note the 600 different part numbers!!!)

Part Number: 24276685 (fits 2011-2012)
Supersession(s): 22781210; 22809287; 22865050; 22914085; 22943277; 23106561; 23248798; 23441757; 23446639

Part Number: 23487635 (fits 2013-2015)
Supersession(s): 22942876; 23136007; 23145307; 23203508; 24286957; 24291478

7de55bfa317023abc9faa9ac5dc09977.png (10.54 KiB) Viewed 13801 times

[Gregski]

so once again I went out and took one for the team and bought this plugulator for it, I know nothing about this particular J1772 gitty up. I assume it's just a dime a dozen Level 1 charger that here in the Independent States it plugs into our 110/120 volt 15 amp wall outlets and makes you wait, or does the General pull some stunts with it? you let us know


actually bought on eBay but they shipped it in a used AMAZON box (just wanted to point that out)

IMG_9480.JPG (31.56 KiB) Viewed 13799 times

IMG_9481.JPG (30.49 KiB) Viewed 13799 times

[Gregski]

YouTube video: Chevy Volt Onboard HV Battery Charger & DC-DC Converter (OBCM & APM)

the one where I stare and compare the Chevy Volt first generation onboard high voltage traction battery charger aka Onboard Charger Module (OBCM) and the DC-DC converter aka the Accessory Power Module (APM) with the second generation ones

[arber333]

so once again I went out and took one for the team and bought this plugulator for it, I know nothing about this particular J1772 gitty up.

There is nothing wrong with your J1772 charging handle/socket. It is a small EVSE. You just lack the integration.
Since you dont yet have DUE wired to your charging soclet you cant use my program for charging.

What you can do is wire up a relay with coil connected to 12V and PP pin on the charging port. Also make sure you connect PE pin to socket GND. So now every time you plug in the handle you pull in the relay. I use that PP signal to jolt my DUE into charging as well.
Now you put a diode on the CP pin of the socket and 2K7 resistor towards GND. Then wire 1K3 resistor in parallel to 2K7 to go through relay towards GND. This way you will signal charging to your EVSE every time you connect the handle.

It is all here in this schematic:
https://en.wikipedia.org/wiki/SAE_J1772 ... ircuit.svg

[Gregski]

What you can do is wire up a relay with coil connected to 12V and PP pin on the charging port. Also make sure you connect PE pin to socket GND. So now every time you plug in the handle you pull in the relay. I use that PP signal to jolt my DUE into charging as well.
Now you put a diode on the CP pin of the socket and 2K7 resistor towards GND. Then wire 1K3 resistor in parallel to 2K7 to go through relay towards GND. This way you will signal charging to your EVSE every time you connect the handle.

Oh wow, thanks for that, so let's break it down, prepare for death by a 1,000 questions:

When you say: "Also make sure you connect PE pin to socket GND." doesn't that happen automagically simply by inserting the shower head thingie into the socket, doesn't that connect the Protected Earth male pin into the corresponding socket's female port (bottom middle on most)

and I'm sorry that's just what them J1772s look like to me

[Gregski]

It is all here in this schematic:
https://en.wikipedia.org/wiki/SAE_J1772 ... ircuit.svg

am I crazy or is the schematic mislabeled, and what is being called Proximity (pin 5) should actually be called Control?

[arber333]

Oh wow, thanks for that, so let's break it down, prepare for death by a 1,000 questions:

When you say: "Also make sure you connect PE pin to socket GND." doesn't that happen automagically simply by inserting the shower head thingie into the socket, doesn't that connect the Protected Earth male pin into the corresponding socket's female port (bottom middle on most)

and I'm sorry that's just what them J1772s look like to me

Am i detecting a salt of irony...?
What i meant was to connect PE pin on your charging socket with your car chassis. Since it is not yet EV that is kind of a must. Doing that will connect aux battery GND/chassis/PE pin together. If you look closely to the J1772 schematic you will notice there is a small 150R (330R) resistor from PP to GND/PE on the EVSE side. PP on the car side is pulled up by a weak (10K) signal so that uC is aware there is nothing connected.
When plug is inserted PP signal is shown GND and it pulls that uC pin to GND signalling connection. Also EVSE will also pull CP pin 1K3 resistor which will command charger power. That is how it works in EVs and how we desire for our conversions...

But if you just need to charge you only need to convince EVSE to open AC power. Which is why you use PP pin as a GND and provide 12V to relay coil when plug is inserted. Provide diode and resistors to the other side of relay...
Or you can just connect diode and 880R from CP to PE.
https://mazdamx3ev.wordpress.com/2018/0 ... nica-evse/