Chevrolet Volt 2 Charger

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1. LV control connector is Molex MX150 P/N 33472-1201

It uses 6 pins out of 12. Pins are Molex MX150 F 18-20AWG P/N 33012-2002 … tor_system

2. HV battery side connector is TE HVA280 P/N 2103628 Key A 2 pole connector … rce=header

3. It seems this is Delphi or Aptive HES 6 Way Device Connector Type 103. P/N 13879048

Pins are P/N 13783301

I took TE HVA280 Key A 2 pole connector with wires from my broken Volvo/Eltek charger. It is the correct key and directly connects to the charger DC side. I also found a kit YHVA280-2PHI-4MM-A

For AC side i ordered Aptive HES 13879048 connector and female pins 13783291 from Mouser. That was available. I will report back when i can try them on.

I needed to find correct HV connector polarity. To get that i performed light bulb method polarity test

I connected HV battery to the charger.

12V LV connector pinout. There are only 6 pins connected inside 12 pin connector:

P2 – GND

P3 – HV voltage sense PWM Frequency 100Hz

P4 – HV Charging Control PWM Frequency 100Hz

When i apply 12V signal at 25% duty charger starts at 1A.

At 60% duty i get 7.6A

Charger can work with PWM from 90Hz to 108Hz.

At 70% duty i get 9.4A which i imagine is the kW limit. After 90% duty charger stops.

P9 – Battery +12v

P10 – Sensed AC Voltage (PWM)

Frequency 100Hz 12V

I cant measure any relavant signal

P11 – 12V Charger Enable Signal could be used for safe BMS disconnect

I will have to investigate feedback signals further, but i must say charger is providing steady power on single phase 230Vac. For safe charging it will require additional means of voltage control, but it is simple to use and control by a steady 100Hz 25% to 90% duty pulse.

I tried to charge 104S batterey at 407Vdc and charger wouldnt start on any PWM duty setting. Shame!