openinverter forum

cancer038 wrote: ↑Mon May 11, 2020 10:35 pm Damien seems to be very busy.

It's important to understand that Damien does not develop or sell 'products' but rather he produces bleeding edge proof of concepts in kit form

Damien's webshop is very clear;

bulletbug wrote: ↑Mon May 11, 2020 10:19 pm Once I understand this, my intention is to help tune up the instructions and FAQ for the gen 2 charger.

That's great

If you're putting time into this can you also try and verify (with others on the forum) whether we have a compatibility issue with some charging stations?

viewtopic.php?f=10&t=489&p=10161#p10161

Kevin Sharpe wrote: ↑Tue May 12, 2020 1:27 pm

bulletbug wrote: ↑Mon May 11, 2020 10:19 pm Once I understand this, my intention is to help tune up the instructions and FAQ for the gen 2 charger.

That's great

If you're putting time into this can you also try and verify (with others on the forum) whether we have a compatibility issue with some charging stations?

viewtopic.php?f=10&t=489&p=10161#p10161

Kevin - Thank you. It looks like the topic you quoted is related to the V5 board. Is that software compatible with the V4 board?

BTW - for anyone waiting on next steps from me, I'm currently waiting on a CAN Bus board to arrive for my stand alone DUE board so I can run CAN capture on the power stage messages. I should have more info this coming weekend.

bulletbug wrote: ↑Wed May 13, 2020 11:54 pm Kevin - Thank you. It looks like the topic you quoted is related to the V5 board. Is that software compatible with the V4 board?

AFAIK the issue relates to all versions of the hardware/software (I checked software versions V2, V4, and V5).

V5 boards use a different microprocessor and the software is not compatible with previous hardware versions.

New rev of the V5 board now with usb onboard for configuration and monitoring.
Also ditched the ULN2003 in favor of the NCV8402 for contactor/relay driving so no more silly 12v feedback through the coils issue.

I like new programming port as well. Just shove the ST link on vs triple checking jumper polarity haha.

Jack Bauer wrote: ↑Mon May 18, 2020 3:44 pm New rev of the V5 board now with usb onboard for configuration and monitoring.
Also ditched the ULN2003 in favor of the NCV8402 for contactor/relay driving so no more silly 12v feedback through the coils issue.

Excellent. Are all backlog and future orders getting this version? Excited to contribute to this one.

Yep all backlog orders and new ones get this rev. Slight delay as the 24pin jst connector is out of stock for another week or two at Mouser.

What size of radiator is appropriate for cooling the charger while it's in use?

Wow, apparently the Tesla charger is capable of V2G (!):
https://electrek.co/2020/05/19/tesla-bi ... -features/

Damien - you know these things better than anyone: would it be possible to run a Tesla charger in DC:AC mode with your board?

clanger9 wrote: ↑Wed May 20, 2020 7:34 am Damien - you know these things better than anyone: would it be possible to run a Tesla charger in DC:AC mode with your board?

Let's discuss that here

bulletbug wrote: ↑Tue May 19, 2020 9:04 pm What size of radiator is appropriate for cooling the charger while it's in use?

Any suggestions on this would be appreciated.

bulletbug wrote: ↑Wed May 20, 2020 12:42 pm

bulletbug wrote: ↑Tue May 19, 2020 9:04 pm What size of radiator is appropriate for cooling the charger while it's in use?

Any suggestions on this would be appreciated.

Damien often uses small oil coolers in his Tesla charger builds. I don't have any direct experience (my Gen 2 chargers are currently not installed) but suspect they need very little cooling.

I use this for cooling both the charger and motor.
https://www.cxracing.com/heat-exchanger/HE001

It is small, but my water pump can flow 150 lpm and is pwm controlled based on temp.

Thank you both for the answers and putting me on the right track

I'm thinking of upgrading to a Tesla gen 2 charger, but note there are several different iterations. Any particular model number that I should be aiming for?

I have 3 phase capability at home.

Boxster EV wrote: ↑Thu May 21, 2020 3:59 pm I'm thinking of upgrading to a Tesla gen 2 charger, but note there are several different iterations. Any particular model number that I should be aiming for?

I have 3 phase capability at home.

Keep in mind these chargers are NOT water proof, the AC in and HV in are just normal unseal able connectors and the lid has no seal on it.

Boxster EV wrote: ↑Thu May 21, 2020 3:59 pm Any particular model number that I should be aiming for?

We don't have a definitive list today.

tom91 wrote: ↑Thu May 21, 2020 4:45 pm Keep in mind these chargers are NOT water proof, the AC in and HV in are just normal unseal able connectors and the lid has no seal on it.

Good point... Gen 3 would be a better choice for many applications

tom91 wrote: ↑Thu May 21, 2020 4:45 pm

Boxster EV wrote: ↑Thu May 21, 2020 3:59 pm I'm thinking of upgrading to a Tesla gen 2 charger, but note there are several different iterations. Any particular model number that I should be aiming for?

I have 3 phase capability at home.

Keep in mind these chargers are NOT water proof, the AC in and HV in are just normal unseal able connectors and the lid has no seal on it.

It can probably live in the boot. European non slave variant best one to go for?

Boxster EV wrote: ↑Thu May 21, 2020 8:42 pm European non slave variant best one to go for?

I don't think anyone has published data after testing the various versions. I'd simply select one from a vendor that has a good returns policy and test the charger as soon as it arrives.

We have lots Gen 2 chargers in the workshop and I will try to test them and publish the results in the next few months.

joromy wrote: ↑Mon May 11, 2020 7:07 pm

bulletbug wrote: ↑Mon May 11, 2020 5:35 pm Line 822 (for phase 1) : dcvolt[0] = ((frame.data.bytes[3] << 8) + frame.data.bytes[2]) * 0.0105286; //we left shift 8 bits to make a 16bit uint.

This is very good finding!!
I have the same voltage conversion with correct voltage reading, but with an European model.
Maybe we should make a list with prod version serial number....

Did you find issues with DC current output restrictions on your charger?

bulletbug wrote: ↑Mon May 11, 2020 5:35 pm
I went back into the software and changed this same multiplier on line 827 (for phase 2) and line 832 (for phase 3).

Upload that and it WORKED! Using my AMP Clamp meter, I was able to see the amps going into the battery pack climb up to 5 amps.

Now I'm seeing that the serial monitor DC Amps (reported by the variable dccur) is inaccurate. When my Amp clamp meter is over the battery packs most negative terminal shows 5 amps the serial monitor is showing less than 0.03 on any single phase.

I'm bumping into temperature shut downs so I'll need to get my water cooling loop in place before I can figure out how to get the displayed dccur sorted out. Not sure it's even important other than on the serial monitor display.

Hi Bulletbug,

In your earlier post you referenced my post where I was experiencing much the same problem as you with mis-scaled DC readings. Glad to hear you got it working!
Unfortunately, I haven't had the same luck with ours. I adjusted the scaling factors on the same lines you've mentioned, such that the serial monitor now correctly displays the pack voltage, but still no charge! I also verified with a clamp meter. Did you make any other changes to the software? Any adjustments to the output voltage scaling perhaps?

I noticed in your pasted read-outs that you were also reading a positive AC current in when in fact none should exist. I also have this symptom but I'm not sure what to make of it. I do know that some amount of power is flowing as the charger gets slightly warm after everything has been plugged in for a while. Let me know if you can think of anything else that would have made a difference to your charger now operating.

Has anyone else found solutions to this problem?

With regards to cooling, we've been able to run 2 of these chargers @ 18kW total with only a small radiator that you might find on a motorcycle and a fan to pull air through.

Cheers,

-Ryan

Cyco90 wrote: ↑Fri May 22, 2020 5:15 am

Hi Bulletbug,

In your earlier post you referenced my post where I was experiencing much the same problem as you with mis-scaled DC readings. Glad to hear you got it working!
Unfortunately, I haven't had the same luck with ours. I adjusted the scaling factors on the same lines you've mentioned, such that the serial monitor now correctly displays the pack voltage, but still no charge! I also verified with a clamp meter. Did you make any other changes to the software? Any adjustments to the output voltage scaling perhaps?

I noticed in your pasted read-outs that you were also reading a positive AC current in when in fact none should exist. I also have this symptom but I'm not sure what to make of it. I do know that some amount of power is flowing as the charger gets slightly warm after everything has been plugged in for a while. Let me know if you can think of anything else that would have made a difference to your charger now operating.

Has anyone else found solutions to this problem?

With regards to cooling, we've been able to run 2 of these chargers @ 18kW total with only a small radiator that you might find on a motorcycle and a fan to pull air through.

Cheers,

-Ryan

Ryan,

Thanks for the info on radiator, that helps a bunch.

To answer your question on "do I have any additional ideas on what your issue might be".

Idea 1: I've seen conflicting information between the install guides vs. forum posts regarding the CAN mode setting configured through the Arduino Serial Monitor. Written instructions say to set it to Master. Posts in forum say that doing so cuts your amperage output in half because it's expecting 2 chargers to be handling the max current you've set.

Idea 2: I also haven't seen any reference in instructions or the forum posts regarding this section of the Gen2V4 code about line 59:

//*********EVSE VARIABLE DATA ******************
byte Proximity = 0;
uint16_t ACvoltIN = 120; // AC input voltage 240VAC for EU/UK and 110VAC for US
//proximity status values for type 1
#define Unconnected 0 // 3.3V
#define Buttonpress 1 // 2.3V
#define Connected 2 // 1.35V

volatile uint32_t pilottimer = 0;
volatile uint16_t timehigh, duration = 0;
volatile uint16_t accurlim = 0;
volatile int dutycycle = 0;
uint16_t cablelim = 0; // Type 2 cable current limit

I have both a 240v single phase EVSE (Juicebox brand) and a 120v charger from my Chevy Spark. The kind that chevy provides. I'm assuming that one is a bit dumber...but it is definitely only at the 120v AC level. The line regarding ACvoltIN was default set to 240v which would/will be problematic for me if I switch back and forth as to which of my chargers I use. I'm guessing that could be addressed through some if statements that would set that variable to a nominal number on each connect cycle, but I'll chase after that later.

Idea 3: This one is still very vague for me, since I haven't chased it around the code to understand how it is used, but the text note off the end is also kind of triggering me. About Line 237:

bChargerEnabled = false; //are we supposed to command the charger to charge?

The question at the end was in the code as I downloaded it, but I don't know who made the comment, why or for what purpose.

Those are my ideas for you to consider, so far.

I'm not a programmer (I imagine I'll be closer to one after this) but I have been working my way through the logic process of the control software. In other words, it's a bit like foreign language that I can read but not yet write.

Anyway, I've been working on the issue for the last 2 days straight. I'm seeing something that I think is related to temperature shut downs. I'm pursuing this idea further today. I say this because the first attempt I make to run the charger each session has confirmed a ramping up to a 5 amp level as seen on clamp meter. Once the My last 2 sessions I have not had water circulation running through but I've been under the idea that I should be able to run it for short periods at 5 amps.

This has not been the case. After, the first successful "ramp up" to 5 amps on the meter, I'm not able to repeat it again until the next session. This is what leads me to think its a temperature related issue shutting down the current push. I'll be hooking water circulation back up today to help eliminate that variable. If I'm understanding the serial monitor lines it is showing my temperatures per phase getting up to 40 C which is 104 F. My ambient garage temps are in the 60 F range right now. Touching the underside of the case, where I assume I should feel some of that heat provides only minimum to no warmth. This brings me to wonder if there may be a C vs F challenge or that temp sensor data from the power stage CAN bus messages is not being translated quite right.

Even when I'm seeing 5 amps on the clamp meter, the DC current showing on the serial monitor is in the .02 to .04 dc amps per each module. I'm assuming (but haven't confirmed) that I should see something in the range of 1.75 amps per module. This is the second variable that I'll start chasing down.

My third active guess at the moment revolves around the power stage can bus messages. I've purchased a CAN tranceiver for my stand alone Arduino Due board for the purpose of logging the power modules CAN traffic. I know the least about doing this, so I'll get to it if these other issues don't bear fruit.

I'm not typically this verbose by nature but I'm hoping that by describing my thoughts and actions in a bit of detail someone more knowledgeable can "pop by" and point out something that I'm missing. I'll post again later today with what I find or don't find today.

- David

Cyco90 wrote: ↑Fri May 22, 2020 5:15 am Did you make any other changes to the software? Any adjustments to the output voltage scaling perhaps?

Ryan - One more thing. I found a mistake in my scaling post as recently as yesterday afternoon. I have since corrected the scaling number mentioned in my post for making my chargers voltage report correctly.