Make Nissan Leaf Gen3 adapter board

[johu]

I think we should do the dual footprints but rearrange some of the added feature pin / openinverter positions to utilize the inner row of thru holes for high current outputs. Any objections? I can also sequence them with the mini mainboard positions to help routing.

Yes, re-arrange the extra pins as you wish, no constraints.

[jrbe]

I think I can flip the contactor planes along with the fets and make it work there with a footprint mod. That leaves the overhang and juggling the pins around as required mods / differences. I'll add connector overhangs and a silkscreen front and back where to trim to if cutting is required for whatever reason.

I realized the pins labeled ending in _NA are new features / openinverter features. Kelju did a good job with what they posted, just challenging working through some of it with no notes.
I added green dots to the 40 pos. connector image I posted - confirmed almost all of the 40 pin to the inlet connector wire colors. Only oddity was 4 grounds in the 40 pin when I only see 3 on the round inlet connector and the Nissan pin out.

I have not been able to find a smd connector datasheet or footprint for the Nissan wire to board headers. Pin spacing ends up 1.109mm to match the image of the old board / dxf I made. TE shows 1.1mm pin spacing. Not a huge difference but over 40 pads later the footprint will end up off. The mechanical thru holes would also likely be off this about .4mm. That's likely a scaling error. I'll rescale it and correct that in both connectors.

[johu]

Sounds good.
1.1mm pad spacing would make sense as the pin spacing is 2.2mm

[jrbe]

Swapping the contactor fet positions & planes worked out well.

The "PRE"charge output connects through the smd pad over to the plated hole. DCSW flows around the +12vsw to the SMD pad and the plated hole on the right side like an h.

Added slots with a 15mm spacing. Going to label the positions too but there's only room for 5 letters.

I'll work on reorganizing the openinverter add on positions on the 40 pos connector to fit / flow better.

[jrbe]

I flipped around the added / open inverter wiring to the 40 pos. Nissan connector. I did not move Nissan positions, only the open inverter features. This worked out well with the dual footprint. It allowed some outputs to have thick traces and align with the mini positioning.

I added a high side switch https://jlcpcb.com/partdetail/TexasInst ... VR/C205990 for the brake output so it will (should?..) output +12v when OUT_BRAKE goes high. There's a 1.8V zener blocking what seems to be 2.5v from the address side of things. Over around 2.7v the zener opens and the high side switch turns on. Thinking if this is supplying +12v when the brake light is supposed to be on in regen people might use it.

Decluttered and removed some outputs that don't seem to exist on the mini (motor protect and out overtemp.)

Added a solder and a physical jumper footprint to be able to select ESP32 programmer voltage with either. I think using 3.3V would allow programming only the ESP32 and won't have to worry about the STM32 blocking programming.


Current schematic is attached if anyone is willing to look at the high side switch / board address circuitry. Going over it in general to look for mistakes would be appreciated.

Gen 3 Leaf Adapter.pdf

(197.48 KiB) Downloaded 70 times

I still need to do the dual 32 position connector footprint.

[jrbe]

This adapter board is done besides verifying LCSC numbers & rotations for JLC and writing up the wiki page on options and using it.

I downloaded all of the different compatible TE headers I was able to find and merged them into one. I colored each different part # as a different color to see where differences are.

Its a slightly odd footprint to merge these together on the 32pos with a P shaped mounting hole. The options are a solder tab like a quick connect male tab (light green below) or a plastic post (red below.) The funny P shaped hole should ideally get plated. We'll see how JLC responds about doing that.
The 40 pos. was fairly easy. If you get one with solder tabs (green below) the plated thru hole will be a lot of solder but doable. I'm not sure if the other style (yellow below) has a screw hole, that's what it seems like.
I could not find the smd footprints, housings, datasheets, etc. I wonder if these are restricted to oem's only.

J8 / JP8 are the voltage select jumpers for programming the ESP32. I left them open so the user decides which voltage and jumper style to use for programming.

johu, want me to put this on github?

[jrbe]

This is done.

[johu]

Awesome, looking very good, thank you very much. Yes put it on github

More via PM

[johu]

And it's here

Basic stuff like wifi is working, will test more in the coming days.

Again thanks very much for all the hard work, it's way better than if I'd done it. All the labels and options etc.

[jrbe]

And it's here

Very happy to see it in real life and to see the funky p shaped plated holes made it through!
Did JLC complain about anything?

[cloudy]

Looks great! How has testing been going?

[johu]

Not at all... as you'll be seeing in the next video the last 4 weeks were pretty much all MEB battery swap. With that mostly done I'll get to it soon

[glink]

If you need help testing please PM me. I have have a test rig and both the 110KW and 160kW inverters available (although they are probably the same without the Nissan brain)