TEG
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Re: Revision 2 upgrade for Nissan EVSE - Allows full level 2

Thu May 19, 2011 3:56 pm

Do we know the gauge of wire from the "control box" to the J1772 handle? Is it suitable for 30A? 24A? 20A? 16A?
Aside from modifying the PWM control signal, what are other limiting factors in the box that would prevent you from going all the way to 30A?
( I assume 30A is the hard limit due to the UL certification of the actual J1772 plug used. )

Obviously the current version of the Leaf means that rates over 16A are of marginal interest, but I wonder if the components in the box and cables are of suitable capability to support 6.6kW for future Leaf's and other 6.6kW capable vehicles?

( In my case being able to charge the RangerEV at full rate would be very handy. )

TEG
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Re: Revision 2 upgrade for Nissan EVSE - Allows full level 2

Thu May 19, 2011 4:02 pm

Another random idea for a rate select... A mercury switch inside the box. Mount flat or vertically for 12A. Position the box upside down (and let gravity do the work) if you want 16A. Or maybe it just defaults to 12A, but each time you rotate the box (during charging) it steps up to the next level. I guess you could use a gyro-sensor instead of a mercury switch. Or make it like the iPod shuffle mechanism where you shake the box vigorously to change rates.

I don't so much like the idea of shorting J1772 pins, or doing a secret handshake with the plug in sequence to select rate.

Another idea - a RF or IR receiver... They make very small close range transmitters and receivers. Maybe one of those "turn off the TV" one button remotes, or an RF doorbell mechanism or garage door opener. Hmmm. Maybe you could program the homelink in the vehicle to send the signal to change rates. There is already a programmable button on the rearview mirror for this! Then the box could have a small piezo speaker to beep different chimes to tell you what rate just got selected. (Higher octaves for higher rates.) Cycle in a loop between 12->16->20->

Sorry, just brainstorming out loud.
Last edited by TEG on Thu May 19, 2011 4:29 pm, edited 1 time in total.

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Re: Revision 2 upgrade for Nissan EVSE - Allows full level 2

Thu May 19, 2011 4:06 pm

Seems the main concern with selectable modes is the 120v operation on a foreign car (since the current LEAF will always do 12a on 120v regardless of what the EVSE tells it), right? How often do you see a 240v circuit that ISN'T at least 20a? Would it be possible to have the programming know it's 120v and set the pilot to 12a, but 20a on 240v? That would alleviate the concerns, if I'm grasping them correctly.

EDIT: Oh, for the Quick220 users, duh. Sorry, wasn't thinking...
Last edited by GeekEV on Thu May 19, 2011 4:57 pm, edited 1 time in total.

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Re: Revision 2 upgrade for Nissan EVSE - Allows full level 2

Thu May 19, 2011 4:46 pm

GeekEV wrote:How often do you see a 240v circuit that ISN'T at least 20a? Would it be possible to have the programming know it's 120v and set the pilot to 12a, but 20a on 240v?
A 20A continuos load on a 20A circuit is most likely going to trip the breaker and is beyond the NEC 125% rule. 16A continuos load on a 20A circuit is the maximum allowed according to the NEC 125% rule. Phil suggested the following in the first post:
Ingineer wrote:4. Presently the unit charges at the standard 12A when used on 120 volt outlets and the full 16A when used on 240 volts.
Phil, perhaps you could create a forum poll to gauge interest in the options you are proposing. 12A/120V and 16A/240V still seems like the sweet spot to me.
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Re: Revision 2 upgrade for Nissan EVSE - Allows full level 2

Thu May 19, 2011 5:02 pm

Spies wrote:A 20A continuos load on a 20A circuit is most likely going to trip the breaker and is beyond the NEC 125% rule. 16A continuos load on a 20A circuit is the maximum allowed according to the NEC 125% rule.
Granted. However most of the common 240v sources we would be using this modified EVSE with are at least 30A... I think it's rare that you'd see a raw L6-20 outlet in the wild and if you installed one yourself just for this, you have control over the breaker.

Of course, flexibility is a good thing, but I'm also a fan of the KISS philosophy...

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Re: Revision 2 upgrade for Nissan EVSE - Allows full level 2

Thu May 19, 2011 5:19 pm

TEG wrote:Do we know the gauge of wire from the "control box" to the J1772 handle? Is it suitable for 30A? 24A? 20A? 16A?
Aside from modifying the PWM control signal, what are other limiting factors in the box that would prevent you from going all the way to 30A?
( I assume 30A is the hard limit due to the UL certification of the actual J1772 plug used. )

Obviously the current version of the Leaf means that rates over 16A are of marginal interest, but I wonder if the components in the box and cables are of suitable capability to support 6.6kW for future Leaf's and other 6.6kW capable vehicles?

( In my case being able to charge the RangerEV at full rate would be very handy. )
As I mentioned before the wiring is #12 AWG throughout. I'm simply not going to consider exceeding 20A with this hardware, so lets take this off the table. I recommend you buy an AV.

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Re: Revision 2 upgrade for Nissan EVSE - Allows full level 2

Thu May 19, 2011 5:21 pm

Spies wrote:
GeekEV wrote:How often do you see a 240v circuit that ISN'T at least 20a? Would it be possible to have the programming know it's 120v and set the pilot to 12a, but 20a on 240v?
A 20A continuos load on a 20A circuit is most likely going to trip the breaker and is beyond the NEC 125% rule. 16A continuos load on a 20A circuit is the maximum allowed according to the NEC 125% rule. Phil suggested the following in the first post:
Ingineer wrote:4. Presently the unit charges at the standard 12A when used on 120 volt outlets and the full 16A when used on 240 volts.
Phil, perhaps you could create a forum poll to gauge interest in the options you are proposing. 12A/120V and 16A/240V still seems like the sweet spot to me.
If I implement selectable modes, then we can have a 20A setting, otherwise we will go with 16A for the reasons above.

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Re: Revision 2 upgrade for Nissan EVSE - Allows full level 2

Thu May 19, 2011 5:25 pm

davewill wrote:Wouldn't the plug/unplug sequence idea open up the possibility of having only a 15amp circuit available, but the device in 16amp mode with no way to change it but plugging it into the car and blowing the breaker? I guess you'd have to assume a 120v socket is always available in those cases. I like both the magnet and paperclip ideas, myself, and can see that the paperclip one is much simpler to execute. I can see where some people might be squeamish about poking around the J1772 with a paperclip, but we're enthusiasts, aren't we!
If I implement the plug-sequence mode switch, then I simply delay output of any pilot signal until the mode switch selection time was passed. Since there will be no pilot signal for the car to acknowledge, there will be no current flowing when changing modes. I could also start off all modes at 8 amps and ramp up over a minute or so.

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Re: Revision 2 upgrade for Nissan EVSE - Allows full level 2

Thu May 19, 2011 5:44 pm

Ingineer wrote:If I implement selectable modes, then we can have a 20A setting, otherwise we will go with 16A for the reasons above.
That makes the most sense. I don't know why we're all fixating on the 20A anyway, like you said, the LEAF can't use it. But more is better right? :lol:

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