Heinz
Posts: 2
Joined: Mon Nov 03, 2014 2:12 am
Delivery Date: 03 Nov 2014

Re: Mini-QC Rapid-Charger (RC) Project for LEAF QC Port

Thu Nov 06, 2014 4:12 am

The pins are beautiful.

I have read through the whole thread (which took me quite a while ;) ) and I noticed that the idea of using server power supplies was abandoned. I still believe that this approach has some potential so I would like to revive the discussion. It looks like CISCO power supplies could be a good starting point. They provide almost all their power on a 42V output and they come in different power ratings up to 8.7kw (continuous). The most interesting one is in fact the 8.7kw unit (WS-CAC-8700WE). It has a 3-phase input and provides all the neat stuff like galvanic isolation, short circuit protection and PFC. It doesn't even need a trigger for starting up. In addition, these units are rated for 300.000h MTBF so they are very sturdy. The unit weighs 18kg so it is still somewhat portable. Specs can be found here:
http://www.cisco.com/c/en/us/td/docs/switches/lan/catalyst6500/hardware/Chassis_Installation/Cat6500/6500_ins/0apwsply.html

There is currently one on ebay for around 400€.

To turn these into a charger we would need to add a DC converter (probably a buck-boost) to step up the charging voltage to 400V and make it adjustable. I have a feeling that this circuit can be relatively simple, small and inexpensive.

I know that 8.7kw is far below the targeted charging power but it is still a lot more than the measly 3.7kw in the 2011 models and even more than the 6.6kw in the newer models. Power could be increased by combining multiple smaller units (e.g. 3x4kw, one per phase). Connecting them in a serial configuration would require modifications to the power supplies (disconnect DC side from AC ground). Connecting them in parallel may kill them (and even if it is possible the currents will exceed 250A) so it's probably not a good idea. It would also become very heavy but might still be usable as a stationary/home charger.

brinkhamer
Posts: 4
Joined: Tue Feb 17, 2015 11:27 am
Delivery Date: 17 Feb 2012

Re: Mini-QC Rapid-Charger (RC) Project for LEAF QC Port

Wed Feb 18, 2015 7:26 pm

garygid wrote:We intend to deliver our work into the public domain, and we
request that our collaborators endorse this same philosophy.




Thanks everyone for sharing this info, it is terribly appreciated.
I've got a plug printing (thanks jclemens!), is there an implementation of a ch@demo controller posted somewhere for reference, or other useful information can message repository that I might have missed somewhere?

brinkhamer
Posts: 4
Joined: Tue Feb 17, 2015 11:27 am
Delivery Date: 17 Feb 2012

Re: Mini-QC Rapid-Charger (RC) Project for LEAF QC Port

Thu Feb 19, 2015 2:14 pm

Heinz wrote:I know that 8.7kw is far below the targeted charging power but it is still a lot more than the measly 3.7kw in the 2011 models and even more than the 6.6kw in the newer models.


This is what I'm hoping to accomplish too, use existing power supplies up to the 10kw range and a buck converter/controller. but so far the messaging part is still pretty cryptic, and it is just a convenience to avoid hacking the battery connectors really.

wk057
Posts: 1
Joined: Fri Feb 27, 2015 6:53 pm

Re: Mini-QC Rapid-Charger (RC) Project for LEAF QC Port

Fri Feb 27, 2015 6:59 pm

Greetings!

I'm an owner of the Tesla Model S, and recently acquired the CHAdeMO adapter. I already have dual changers in the car and can charge at 20kW from 240VAC/80A, and supercharging is enabled for DC charging.

However, I've been working on a large off-grid solar project that has roughly 4000Ah of 48VDC battery storage (salvage modules from totaled Tesla Model S), over 44kW of PV input, and 64kW worth of off-grid DC->AC inverters. Ideally, I'd love a complete DC->DC charging solution, a possibility opened up by the CHAdeMO adapter since it supports DC charging up to 50kW/125A. I figure DC->DC would have to be more efficient, and possibly higher power, than DC->AC->DC that is done with normal at home charging @ 240VAC/80A from my inverter bank. (Some details here on the TMC forum: http://www.teslamotorsclub.com/showthre ... post916002)

Fortunately with the Tesla I have no need to build a CHAdeMO connector. I can simply dismantle the adapter and make direct connections if desired. (After buying a second adapter for this purpose that is, hehe)

Anyway, unfortunately I don't have time to read this thread's dozens of pages and hundreds of posts... but how are you folks making out with this? Any hope for my 40-50VDC input 40-50kW CHAdeMO charger using anything you guys have come up with? :)

Someone at the TMC forum directed me here when I started a thread about a DIY CHAdeMO charger ( http://www.teslamotorsclub.com/showthre ... ng-Station )

Thanks. :)

-wk

pachai126
Posts: 2
Joined: Wed Dec 30, 2015 7:40 am
Delivery Date: 04 Jan 2016
Leaf Number: 415359
Location: Passaic, NJ

Re: Mini-QC Rapid-Charger (RC) Project for LEAF QC Port

Sun Jan 10, 2016 10:18 am

Hello veteran Leafers!
I took delivery of a 2013 Leaf S WITH Chademo and 6 KW charger
on MONDAY in Virginia. And had an adventure driving it back
to Northern NJ - 277 miles in in 60-mile increments.

I guess trying to get 84 miles to a charge (or 100!)
was optimistic for a new Leaf owner.

Although work should be an easy trip,
I REALLY would love to be able to get a bit more range.

I am here to learn about and perhaps help
with building/testing a Chademo "Dump Charger."
My Camry EV project got stuck in the long list of todos for it
and other unrelated projects...

So, I have 50 Thundersky 100Ah cells available
to see if they fit in the trunk or on a cargo tray
That would be about 18.2KWh = about 55-60 mi.
I have a Manzanita Micro PFC charger for the cells.

On Wednesday, I drive to work with 2 other adults.
Going, I used local streets which saves energy
and bypasses the 3 miles of traffic at the George
Washington Bridge. No time was lost in that choice.
At work, the meter said I had 45 miles. The trip is 30.
So, I used the highway and had heat on.
When I dropped off my carpool guy, I had 7 miles.
When I turned the corner and went up the hill
to my house (3 blocks), it went to empty.

I am still learning how to conserve energy,
mostly in Accessories.

On Thursday, I had a brief conversation with my boss.
I had asked about EV charging 8 years ago...
He said to talk to the CFO, and it will happen :-)
Other divisions of our organization have L2 in
their paid parking lots. (If I had a meeting there,
I could park for free)

I am quite flexible. If they give me an outlet,
I'll be able to get home. If they give me an L2,
I'll be able to go visit my brother up in Yorktown after work :-)
If they give me a DCQC..... :-)


I don't know a lot about power supplies,
but I do know a bit about communication...
I do UNIX Systems Integration for a hospital.

(I actually learned in school how to calculate
the bandwidth of a T1 circuit, 1/4 century ago :-)


Seth
in Northern NJ

pachai126
Posts: 2
Joined: Wed Dec 30, 2015 7:40 am
Delivery Date: 04 Jan 2016
Leaf Number: 415359
Location: Passaic, NJ

Re: Mini-QC Rapid-Charger (RC) Project for LEAF QC Port

Sun Jan 10, 2016 10:59 am

PS another thought....

It sounds like the communication protocol for Chademo is almost
reverse-engineered....I imagine there should be documentation on
Combined Charging System DC fast charging.

Would it be possible to build a black box, a dongle,or an adapter
that plugs into the Chademo socket and accepts a CCS?
Or perhaps it spans the J1772 and the Chademo and presents a CCS.

(or for that matter, Tesla Super Charger port :-)

Likewise, I would like to have the ability to use
L2 or Chademo or CCS to recharge my dump charger pack ...

I could drive 1.5 hours, stop at a scenic overlook and dump charge,
drive another 1.5 hours to a full service stop, hook the car
to the Chademo or CCS, and hook the dump charger up to L2 charging....

User avatar
TonyWilliams
Posts: 9970
Joined: Sat Feb 19, 2011 1:48 am
Location: San Diego
Contact: Website

Re: Mini-QC Rapid-Charger (RC) Project for LEAF QC Port

Mon Jan 11, 2016 11:54 am

pachai126 wrote:PS another thought....

It sounds like the communication protocol for Chademo is almost
reverse-engineered....I imagine there should be documentation on
Combined Charging System DC fast charging.


There's nothing to "reverse engineer"... use the actual documention from the CHAdeMO Association or from SAE.

Would it be possible to build a black box, a dongle,or an adapter
that plugs into the Chademo socket and accepts a CCS?



Of course. How much time and money do you want to devote to this?


Or perhaps it spans the J1772 and the Chademo and presents a CCS.



This sounds far more expensive and clunky.


(or for that matter, Tesla Super Charger port :-)



What exactly would that do for you?


Likewise, I would like to have the ability to use
L2 or Chademo or CCS to recharge my dump charger pack ...



$$$$

minispeed
Posts: 680
Joined: Sun Jul 06, 2014 4:52 am
Delivery Date: 15 Jul 2014
Location: Ancaster, ON

Re: Mini-QC Rapid-Charger (RC) Project for LEAF QC Port

Mon Jan 11, 2016 5:35 pm

pachai126 wrote:
So, I have 50 Thundersky 100Ah cells available
to see if they fit in the trunk or on a cargo tray
That would be about 18.2KWh = about 55-60 mi.
I have a Manzanita Micro PFC charger for the cells.


I think your best bet to use these would be to rig them up to provide power for an EVSE. If you're parked at work for at least 5 hrs even if they are just supplying the 120v 1kWish unit that comes with that car that will put 1kWh into the battery for every hour you're parked, or about 4.5%.

It would be best to size it so that you aren't hauling extra weight that you don't need so that the batteries have maybe 10-20% more capacity than what you use in a full work day.

If you want more single charge range it would become much more complex.

pachai126 wrote:On Wednesday, I drive to work with 2 other adults.
Going, I used local streets which saves energy
and bypasses the 3 miles of traffic at the George
Washington Bridge. No time was lost in that choice.
At work, the meter said I had 45 miles. The trip is 30.
So, I used the highway and had heat on.
When I dropped off my carpool guy, I had 7 miles.
When I turned the corner and went up the hill
to my house (3 blocks), it went to empty.


Don't pay any attention to the miles left on the gauge, or Guess O Meter (GOM). Use the % gauge and start to learn the different legs of your trip that take different amounts. On every trip reset the mile/kWh gauge. Do a reset for to work and for home. One will almost always be higher, that's the uphill leg and/or against the prevalent winds(unless your home and work are at the same elevation and there isn't much wind). It's easier to live with the leaf when your return trip is the one that requires less juice as the error in the GOM will favour you. We really are getting off topic here but you can read about it in other posts and continue with questions there.
2015 White SV, after one month 292 GIDS
Best 1 charge drive, 229km (143miles)

dwl
Posts: 18
Joined: Tue Jan 05, 2016 5:06 pm
Delivery Date: 08 Jan 2016
Leaf Number: 112097
Location: New Zealand

Re: Mini-QC Rapid-Charger (RC) Project for LEAF QC Port

Fri Mar 25, 2016 7:53 pm

I hope I am not causing any inconvenience by posting to an old thread but I am hoping to tap into the wealth of knowledge that is out there and this might be relevant to this project.

Here in New Zealand we have started to see more DCQC being installed with the first in our capital city Wellington opened two days ago. We have an issue with the charge finish level, especially when the DCQC is set to 80% on the 2011-2012 Leafs that are sourced via Japan and as it has now been seen on two different makes of CHAdeMO DCQC it might also be relevant to more DCQC like this project.

The symptoms are with a 80% termination set on the charger a 2014 Leaf works as expected and charge terminates at 80% on the car dash display and about 80% SOC on Leaf Spy. For the 2011-2012 models the charge stops at lower levels - e.g. "When the fast charger was done leaf spy pro reported battery charge statuses of 73, 73, and 70% in the 3 cars. We also tried charging 2 of the leafs to maximum on the fast charger, which turned out to be 95% on the fast charger screen. That gave 86.7% and 80.1% SOC for the 2 leafs"

The chargers display the SOC which I assume is being signalled from the car although I have not yet found any obvious reference to this message type in these threads. There is discussion on this issue at https://www.facebook.com/groups/NZEVOwners/permalink/1674356442831663/

There are indications that some of the firmware updates to the 2011-12 Leafs might be relevant but there may be differences between the US and Japan market models. Can anyone please advise whether there have been issues with different reported SOC values between DCQC and Leaf Spy for 2011-12 models and if so the improvement achieved for which firmware update.
2014 S - 6000 km Jan 2016; 23000 km Sept 2016; 93% SOH

N0GAS
Posts: 1
Joined: Sat Mar 26, 2016 11:26 pm
Delivery Date: 27 Mar 2012
Leaf Number: 060142

Re: Mini-QC Rapid-Charger (RC) Project for LEAF QC Port

Sat Mar 26, 2016 11:29 pm

Hi Don.

Its a very complex issue. Its CANBUS messages and HOW they are interpreted.

A software update won't fix it, its the controller itself.

Early Leafs and Veefill are not 100% compatible, welcome to being an early adoptor :)

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