I bought a Chevy Volt Gen1 DC-DC Converter - Now What? Topic is solved

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Re: I bought a Chevy Volt Gen1 DC-DC Converter - Now What?

Post by Gregski »

Request For Comments Please ( RfCP ) lol

Would one of these cut off cables pictured below of what is claimed to be a Chevy Volt 2011-2015 battery Charger be what we are looking for? Asking to see if so, which one of us would be the one to hold this eBayer down while the other gives them a wedgie?

Disclaimer: the only reason I am beating this cable horse to death is in the name of Science and full disclosure, I personally really don't care but I want us all to know what goes where and how it all connected from the factory so that we can all make our own decisions, also I do like things to just plug and play using the OEMish orange plugs when possible

a link to a wonderful write up by our very own Arber Kramar on how to control it using CAN bus Ampera Charger

a link to Damien Maguire's GitHub to download the Arduino UNO code to run this gen 1 charger using CAN Bus AmperaCharger
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Re: I bought a Chevy Volt Gen1 DC-DC Converter - Now What?

Post by Gregski »

this may be the wrong Generation but it is a mind blowing video in terms of effort and quality so I had to share it


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Re: I bought a Chevy Volt Gen1 DC-DC Converter - Now What?

Post by Gregski »

I think we just hit the Mother Load, here is Mark Weisheimer presenting Apm Demo 1

Chevy Volt APM Accessory Power Module demo of CAN command DC/DC converter
Complete documentation for the CAN control and electrical connections are at:
forums.EVTV.me
in the Chevy Volt parts forum.

Key Take Aways:
  • the original 12 volt car battery was the AGM technology which uses a more aggressive/higher charging voltage
  • this DC-DC Converter has the power of two big car alternators


Mark used this tool in his demonstration: MICROCHIP APGDT002 CAN BUS ANALYZER TOOL, CAN 2.0B, ISO11898-2 or one like it, it may have been the older ver 1
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Re: I bought a Chevy Volt Gen1 DC-DC Converter - Now What?

Post by arber333 »

Gregski wrote: Thu Feb 17, 2022 3:40 pm Complete documentation for the CAN control and electrical connections are at:
forums.EVTV.me
in the Chevy Volt parts forum.
EDIT:
Well EVTV forum is not available anymore, i have reposted many of those instructions here under GM applicable thread.
Also i have data in my site for APM and Volt charger...
https://leafdriveblog.wordpress.com/201 ... dc-or-apu/
https://leafdriveblog.wordpress.com/201 ... a-charger/
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Re: I bought a Chevy Volt Gen1 DC-DC Converter - Now What?

Post by Boxster EV »

arber333 wrote: Thu Feb 17, 2022 6:06 pm
Gregski wrote: Thu Feb 17, 2022 3:40 pm Complete documentation for the CAN control and electrical connections are at:
forums.EVTV.me
in the Chevy Volt parts forum.
Well not only, i have reposted many of those instructions here under GM applicable thread.
Also, both charger and DCDC code in Tom de Bree's Chevy Volt BMS code.
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Re: I bought a Chevy Volt Gen1 DC-DC Converter - Now What?

Post by Gregski »

Boxster EV wrote: Fri Feb 18, 2022 3:25 pm
arber333 wrote: Thu Feb 17, 2022 6:06 pm
Gregski wrote: Thu Feb 17, 2022 3:40 pm Complete documentation for the CAN control and electrical connections are at:
forums.EVTV.me
in the Chevy Volt parts forum.
Well not only, i have reposted many of those instructions here under GM applicable thread.
Also, both charger and DCDC code in Tom de Bree's Chevy Volt BMS code.
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Re: I bought a Chevy Volt Gen1 DC-DC Converter - Now What?

Post by Gregski »

folks I just luv this community literally as we're doing this write up, Miss Fit is dropping one of these Volt DC-DC Converters in a BMW e46, so why don't we show our support by checking it out:


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Re: I bought a Chevy Volt Gen1 DC-DC Converter - Now What?

Post by arber333 »

Gregski wrote: Fri Feb 18, 2022 5:21 pm folks I just luv this community literally as we're doing this write up, Miss Fit is dropping one of these Volt DC-DC Converters in a BMW e46, so why don't we show our support by checking it out:
That module at 5:30 is Volt gen2 charger NOT DCDC converter.
https://openinverter.org/forum/viewtopi ... =25&t=1690

DCDC gen2 converter comes on only later at 14:32 in video.
https://openinverter.org/forum/viewtopic.php?f=25&t=978
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Re: I bought a Chevy Volt Gen1 DC-DC Converter - Now What?

Post by Gregski »

arber333 wrote: Fri Feb 18, 2022 7:32 pm
Gregski wrote: Fri Feb 18, 2022 5:21 pm folks I just luv this community literally as we're doing this write up, Miss Fit is dropping one of these Volt DC-DC Converters in a BMW e46, so why don't we show our support by checking it out:
That module at 5:30 is Volt gen2 charger NOT DCDC converter.
https://openinverter.org/forum/viewtopi ... =25&t=1690

DCDC converter comes on only later at 14:32 in video.
https://openinverter.org/forum/viewtopic.php?f=25&t=978
crap, I had it right the first time, these below are Chargers not converters?
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Re: I bought a Chevy Volt Gen1 DC-DC Converter - Now What?

Post by Gregski »

and listings such as this one sure don't help none, but hang in there folks we're gonna make sense of this just wait

converter inverter charger.jpg
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Re: I bought a Chevy Volt Gen1 DC-DC Converter - Now What?

Post by Gregski »

alright, tell me this is the Gen 2 onboard battery charger part #24275451, and we all can be friends again, ha ha

(boy I hate learning more than I have to, my brain hurts)

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Re: I bought a Chevy Volt Gen1 DC-DC Converter - Now What?

Post by EV_Builder »

The long air cooled unit is a DC/DC converter. You recognize the DC/DC ones often haveing the M8 studd for the 14VDC output.

The water-cooled , compact box is the charger. It's single phase 3kw and PWM driven I think 400volts max. (96S).
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Re: I bought a Chevy Volt Gen1 DC-DC Converter - Now What?

Post by Gregski »

EV_Builder wrote: Sat Feb 19, 2022 11:00 am The long air cooled unit is a DC/DC converter. You recognize the DC/DC ones often haveing the M8 studd for the 14VDC output.

The water-cooled , compact box is the charger. It's single phase 3kw and PWM driven I think 400volts max. (96S).
thanks for trying to help I know I am sounding like a buffoon here so please allow me to say it in pictures:

Gen 1 Charger labeled.jpg
IMG_8463 labeled.jpg
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Re: I bought a Chevy Volt Gen1 DC-DC Converter - Now What?

Post by EV_Builder »

The upper picture doesn't reveal if there are studs on the other side so i don't know i just saw your others pictures,,its a charger.

I do know that there is a water-cooled DC/DC too, its on splash screen of your video...

For your build you should check the voltages and the control interface too. Some are Can-bus others are PWM.
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Re: I bought a Chevy Volt Gen1 DC-DC Converter - Now What?

Post by Gregski »

alright so I'm not completely crazy, GM does use 57 different part numbers for the Volt second Gen DC-DC Converter

Part Number: 24284603
Supersession(s): 24274770; 24280796; 24290992
https://www.gmpartsmog.com/p/70072595/24284603.html

Location in OEM vehicle: in the trunk

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trunk.PNG

some great info on it here: Volt Gen2 DCDC
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Re: I bought a Chevy Volt Gen1 DC-DC Converter - Now What?

Post by Gregski »

similarly GM does use multiple part numbers for the Volt second Gen battery charger

Part Number: 24281923
Supersession(s): 24277705


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

Location in OEM vehicle: in the trunk

CT16167_6.png
trunk.PNG

some great info on it here: Chevy Volt Gen2 Charger
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Re: I bought a Chevy Volt Gen1 DC-DC Converter - Now What?

Post by Gregski »

so I just pulled the trigger on a Chevy Volt Gen 2 charger (2016-2019) I did it for the following reasons

1. the price was right, the eBayer accepted my offer of $100 bucks

2. the eBay seller was local, and I could pick it up

2b. since the seller was local I wanted to see if I can establish a relationship with them and have a source for EV parts

3. I learn by comparison so I look forward to starring and comparing this one to a Gen 1

4. I like to buy in to an eco system, and not mix components if I don't have to, so for better or worse I favor a Volt DC-DC converter with a Volt Charger pairing

5. have you seen their mascot? how can you say no to those eyes?

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Re: I bought a Chevy Volt Gen1 DC-DC Converter - Now What?

Post by Gregski »

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 (heard it was in the trunk)

2. where is the converter located

3. how are those two connected (does the inverter serve as the middle woman)

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

ALLDATA DIY 1.jpg
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Hybrid Controls.jpg
Hybrid Controls 2.jpg
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Re: I bought a Chevy Volt Gen1 DC-DC Converter - Now What?

Post by Gregski »

and here are the key components labalized, I am now on a mission to find the part numbers for cables #14 and 15, please stand by ~ The Greg is on the case

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Re: I bought a Chevy Volt Gen1 DC-DC Converter - Now What?

Post by arber333 »

Gregski wrote: Fri Feb 25, 2022 3:01 pm I had questions:

1. where is the onboard charger even located (heard it was in the trunk)
2. where is the converter located
3. how are those two connected (does the inverter serve as the middle woman)
4. what does the charge port connect to, does it plug in directly to the charger
1. Chevy Volt gen1 has its charger in the right front wheel well just behind bumper. I would assume this is the reason gen1 chargers are so hard to get and so $$$. They simply do not survive front impact.
In the gen2 Volt both charger and converter are located in the trunk together. Distance between them is minimal.
https://www.diyelectriccar.com/threads/ ... st-1029757

2. DCDC in gen1 is located behind the rear seats in the trunk under the shelf. Its cooling system takes quite a lot of space...
https://s19533.pcdn.co/wp-content/uploa ... s-Volt.jpg

3. HPCM2 module is the decision maker for charger and DCDC converter. In Gen1 both are run via CAN bus so HPCM2 module keeps communication with them and BMS. While in gen2 both charger and DCDC are run via about 100hz signal from HPCM2. Its all vary similat to computer cooling fan control. When PWM duty is increased voltage/power also increase. Located under the right seat...
https://nemigaparts.com/cat_spares/epc/opel/r12/p1/6/

4. Charger port is connected directly to charger via its AC lines. Control lines go to HPCM2 module which turns on/off DC charging relay. There is no contactor between charger as EVSE takes care of the switching power.

EDIT: Both cables 14 and 15 go from the front of the battery under the car along the brake lines or fuel lines towards its own device. Both are packed inside long alu tube which is a pain to get off. When i was taking those cables apart i simply tore them off as far from connector as i could. Normally you are left with about 12cm of cable to splice on your wires. Its not worth the trouble unless you get someone to sell you the complete tube...
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Re: I bought a Chevy Volt Gen1 DC-DC Converter - Now What?

Post by Gregski »

arber333 wrote: Fri Feb 25, 2022 3:27 pm
Gregski wrote: Fri Feb 25, 2022 3:01 pm I had questions:

1. where is the onboard charger even located (heard it was in the trunk)
2. where is the converter located
3. how are those two connected (does the inverter serve as the middle woman)
4. what does the charge port connect to, does it plug in directly to the charger
1. Chevy Volt gen1 has its charger in the right front wheel well just behind bumper. I would assume this is the reason gen1 chargers are so hard to get and so $$$. They simply do not survive front impact.
In the gen2 Volt both charger and converter are located in the trunk together. Distance between them is minimal.
https://www.diyelectriccar.com/threads/ ... st-1029757

2. DCDC in gen1 is located behind the rear seats in the trunk under the shelf. Its cooling system takes quite a lot of space...
https://s19533.pcdn.co/wp-content/uploa ... s-Volt.jpg

3. HPCM2 module is the decision maker for charger and DCDC converter. In Gen1 both are run via CAN bus so HPCM2 module keeps communication with them and BMS. While in gen2 both charger and DCDC are run via about 100hz signal from HPCM2. Its all vary similat to computer cooling fan control. When PWM duty is increased voltage/power also increase.

4. Charger port is connected directly to charger via its AC lines. Control lines go to HPCM2 module which turns on/off DC charging relay. There is no contactor between charger as EVSE takes care of the switching power.
1,000 thanks for that, and the links are brilliant I think I am going to borrow some of those pics, so odd for Volt to move away from CAN control back to PWM in gen 2, at least to me and I know zero about electronics

converter.png
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Re: I bought a Chevy Volt Gen1 DC-DC Converter - Now What?

Post by arber333 »

Gregski wrote: Fri Feb 25, 2022 3:31 pm 1,000 thanks for that, and the links are brilliant I think I am going to borrow some of those pics, so odd for Volt to move away from CAN control back to PWM in gen 2, at least to me and I know zero about electronics
No sweat :)...
I expect car manufacturers want to cut cost at every corner. Just look at VW with its LIN bus. What is wrong with CAN bus... well i guess royalties are high and integration is more complex than simple PWM signal. Specially if that signal does not need to change a lot. And DCDC can keep that signal at stable 75% duty for 14V power.
Also i expect changer signal does not move a lot. Maybe 5 times within charge cycle?
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Re: I bought a Chevy Volt Gen1 DC-DC Converter - Now What?

Post by 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

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Re: I bought a Chevy Volt Gen1 DC-DC Converter - Now What?

Post by Gregski »

and this is the gen 1 Converter to High Voltage (HV) "traction" battery cable part # 23432013 it appears to run from the back of the vehicle ie the trunk along the side of the HV battery to the front of it where it plugs in

Supersession(s): 22744389; 22827021

Lessons Learned from me in the future: This cable is encased in a metal / aluminum tube and is about 7 feet long, hence why it may cost so much on eBay or the shipping may make it cost prohibitive, I will post actual pics of it below!

Also if you look at how it is actually connected on the inside to the circuit board, you can ditch the orange rectangular plug and hard wire it inside with two ring terminals and call it good, since that's how they did it on the older version.


newer.jpg
older.jpg
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below we see just the tail end of a much much longer high voltage cable that connects the DC-DC converter in the trunk of the vehicle to the front of the battery pack right below the engine firewall, using a high voltage cable encased in a metal tube
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Re: I bought a Chevy Volt Gen1 DC-DC Converter - Now What?

Post by Gregski »

wait, what now? what kinda contraband is this, and why are we dealing with the cartel?

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