miscrms
Posts: 142
Joined: Fri Sep 05, 2014 10:25 am
Location: Phoenix, AZ

2012 Leaf Charge Failure CAN Capture

Fri Nov 27, 2015 1:00 am

Hello all,

If any one is willing I could use some help figuring out what might be keeping my "Leaf" from charging, and also thought the CAN data captured might be of interest to those working on documenting the CAN messages in the Leaf.

Background: This is a 2012 Nissan Leaf drive system that was removed from a salvaged vehicle. It was fully functional before teardown, and now I am reassembling it on a tabletop for testing outside the vehicle. I was pretty lucky to find one that had both cosmetic and frame damage, but no major functional issues I could find.

Status: The system is wired up with most major systems with the primary exceptions of the braking, steering, cooling, and HVAC. Most of these omissions were successfully tested while still in the vehicle, but its possible one of them is interfering with charging. The system will go ready, shift into gear, and respond to the accelerator. After powering down, I must clear the DTCs P31C8 and P31C9 (VCM errors related to the normal charge relays) before it will go ready again. Not sure why these DTCs would occur in ready / drive.
More details here on other DTCs observed and current setup if helpful:
http://www.diyelectriccar.com/forums/sh ... stcount=62

When plugging in the charge cable (L1) the system appears to power up as expected, the EVSE light goes to charging, and the first charge indicator starts flashing. However, according to both LeafSpy and my Watt meter the charger never ramps up power, and after about a minute the system shuts down. The EVSE goes back to ready, no fault. The same two DTCs P31C8 and C9 must be cleared from the VCM before it will start charging again. I have manually operated both normal charge relays from the OBC connector by shorting the control pins to GND in "power on" mode. Monitoring the control voltages during charge startup the OBC does not appear to be attempting to close the relays. Its also important to note that the DTCs observed are VCM errors, not OBC errors. If I disconnect one of the normal charge relays coil connectors then I get a DTC from the OBC. Lastly I've verified that the OBC connectors appear to have 12V power and GND on all expected pins.

CAN Data: I'll figure out a way to post my dumps and share the links, but here are some observations. I've had to split the dumps into 2 parts, one covering the beginning of a charge, and one covering the end, as my program can only handle 9999 messages and I didn't want to filter until I knew what to look for.

0.0s 1F2 [2] 00 (Ready?) [1] 64 (Min Chg Power Commanded?)
0.2s 1DB BVS=511
0.2s 1DC Max CHG CUR 11111111111 (maybe anomalous, byte 0=FF)
0.3s 1DB BVS=371 (measured 370V)
0.4s 5BF [2] (OBC Status?) 00010000, [1] (line voltage?) 00, [3] (HV@OBC?) 00, [6] (Charge current?) 00
0.4s 1F2 [2] 20 (Charge?) [1] 64 (Min Chg Power Commanded?)
0.5s 5BF [2] (OBC Status?) 00011000, [1] (line voltage?) 00, [3] (HV@OBC?) 00, [6] (Charge current?) 00
0.6s 5BF [2] (OBC Status?) 01000000, [1] (line voltage?) 00, [3] (HV@OBC?) 00, [6] (Charge current?) 00
0.8s 5BC GIDs=1022
0.9s 5BF [2] (OBC Status?) 01000000, [1] (line voltage?) 00, [3] (HV@OBC?) 67, [6] (Charge current?) 00
1.0s 1DC Max CHG CUR 00111111111 (maybe anomalous, byte 0=FF)
1.0s 5BF [2] (OBC Status?) 01000000, [1] (line voltage?) 3C, [3] (HV@OBC?) 6F, [6] (Charge current?) 00
1.1s 5BF [2] (OBC Status?) 01000000, [1] (line voltage?) 95, [3] (HV@OBC?) 6F, [6] (Charge current?) 00
1.5s 5BC GIDs=82 Consistent with LeafSPy and Voltage
1.7s 5BF [2] (OBC Status?) 01001000, [1] (line voltage?) 97, [3] (HV@OBC?) 6F, [6] (Charge current?) 00
2.0s 5BF [2] (OBC Status?) 01001000, [1] (line voltage?) 96, [3] (HV@OBC?) 70, [6] (Charge current?) 00
15.5s 5BF [2] (OBC Status?) 01001000, [1] (line voltage?) 96, [3] (HV@OBC?) 70, [6] (Charge current?) 00 END OF FIRST DUMP
15.6s 1F2 [2] 20 (Charge?) [1] 64 (Min Chg Power Commanded?)

0.0s 1DC Max CHG CUR 00000111101 (probably correct, byte 0=6E)
0.0s 1F2 [2] 20 (Charge?) [1] 64 (Min Chg Power Commanded?)
0.0s 5BF [2] (OBC Status?) 01001000, [1] (line voltage?) 96, [3] (HV@OBC?) 70, [6] (Charge current?) 00 Beginning Second Dump
3.5s 5BF [2] (OBC Status?) 01010000, [1] (line voltage?) 96, [3] (HV@OBC?) 70, [6] (Charge current?) 00
3.6s 1F2 [2] 60 (???) [1] 64 (Min Chg Power Commanded?)
3.6s 5BF [2] (OBC Status?) 01110000, [1] (line voltage?) 96, [3] (HV@OBC?) 70, [6] (Charge current?) 00
3.8s 5BF [2] (OBC Status?) 01110000, [1] (line voltage?) 6C, [3] (HV@OBC?) 70, [6] (Charge current?) 00
3.9s 5BF [2] (OBC Status?) 01110000, [1] (line voltage?) 30, [3] (HV@OBC?) 70, [6] (Charge current?) 00
4.0s 5BF [2] (OBC Status?) 01110000, [1] (line voltage?) 00, [3] (HV@OBC?) 70, [6] (Charge current?) 00
4.9s 5BF [2] (OBC Status?) 01110000, [1] (line voltage?) 00, [3] (HV@OBC?) 4B, [6] (Charge current?) 00
5.0s 5BF [2] (OBC Status?) 01110000, [1] (line voltage?) 00, [3] (HV@OBC?) 00, [6] (Charge current?) 00
5.5s 1F2 [2] 00 (Ready?) [1] 64 (Min Chg Power Commanded?)
5.5s 5BF [2] (OBC Status?) 00110000, [1] (line voltage?) 00, [3] (HV@OBC?) 00, [6] (Charge current?) 00
16.2s 5BF [2] (OBC Status?) 00110000, [1] (line voltage?) 00, [3] (HV@OBC?) 00, [6] (Charge current?) 00 END OF SECOND DUMP

So it could be that the VCM is never instructing the OBC to ramp up based on constant 64 value in 1F2 Byte 1? Its also strange that the 5BF byte 3 value is 70, which if the equation for HV voltage at OBC in the spreadsheet is correct only translates to 322V. Not sure why their would be any HV there at all if the normal charge relays aren't closing, and why it would be so much lower than the reported (and measured) battery voltage. Unless perhaps that is the actual OBC min output voltage with no load or something.

The behavior of 5BF byte 2 is very interesting, it definitely looks like each bit may correspond to the state of a particular OBC element (perhaps being reported to VCM?) as mentioned in the spreadsheet. There are many more states seen here on other bits than in the spreadsheet though.

Anything jump out at anyone, or anything else I should look at?

Thanks,
Rob

miscrms
Posts: 142
Joined: Fri Sep 05, 2014 10:25 am
Location: Phoenix, AZ

Re: 2012 Leaf Charge Failure CAN Capture

Fri Nov 27, 2015 1:13 am

The raw CSV files are posted here:
http://www.diyelectriccar.com/forums/at ... 1448611534

If that doesn't work they are attached to this post:
http://www.diyelectriccar.com/forums/sh ... stcount=70

Will try to find a better place to host.

Rob

jpadc
Posts: 275
Joined: Sat Dec 13, 2014 7:25 am
Delivery Date: 20 Dec 2014
Location: Indiana & Wisconsin

Re: 2012 Leaf Charge Failure CAN Capture

Sat Nov 28, 2015 3:22 am

Way out of my league here, and I have no idea what parts you have working and not so this is just a random guess. You say it never ramps up charging and quits after a minute. Are you sure there was not a charging timer set in the car that is still set? Have you just left it plugged in over a 24 hour period to see if it starts charging on its own at some point in time? Do you have the components necessary to check for a charge timer setting?
2018 Leaf SV /w Tech & Climate Packages - Purchased in Feb, 2020
My previous car was a 2013 Leaf S /w Charge Package - Purchased new in Iowa City Dec. 2014

miscrms
Posts: 142
Joined: Fri Sep 05, 2014 10:25 am
Location: Phoenix, AZ

Re: 2012 Leaf Charge Failure CAN Capture

Sat Nov 28, 2015 3:34 am

Hey jpadc, thanks for trying to help! Luckily I solved it :)

The issue was that the Heater and Charger HV connectors were reversed at the DC junction box. Apparently they are the same connector and I had only labeled them DCJB ;)

All working as it should now.

Rob

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