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A peek at the Leaf's Charger

Posted: Tue Mar 15, 2011 5:37 pm
by Ingineer
Did some nosing around to satisfy curiosity, and here's what I found:


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With the "hump" cover removed.


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Here's the back of the Charger. You can see the water cooling lines entering from the bottom and the cooling channels in the aluminum casting.


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Here you can see they added in an EMI filter. This is not shown in the service manual. The wiring from the front of the car appears to be about 12awg. The 2 small black wires are the pilot signal from the EVSE and the handle interlock.


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The Charger is made by Nichicon.


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This is the other major thing in the "Hump". It's the Panasonic brake backup supercapacitor assembly. Very similar to what's in the Prius, only larger.

-Phil


-Phil

Re: A peek at the Leaf's Charger

Posted: Tue Mar 15, 2011 5:43 pm
by mwalsh
Cool! Not something I'd consider doing myself, but glad you did! :D

Re: A peek at the Leaf's Charger

Posted: Tue Mar 15, 2011 5:45 pm
by derkraut
Hey Ingineer-----thanks for the informative info. :)

Re: A peek at the Leaf's Charger

Posted: Tue Mar 15, 2011 5:53 pm
by smkettner
So then... would a replacement (6+ kw) be a do it yourself project?

Re: A peek at the Leaf's Charger

Posted: Tue Mar 15, 2011 5:53 pm
by DaveEV
Nice! That beefy round bar should also help stiffen up chassis a good deal, too.

Re: A peek at the Leaf's Charger

Posted: Tue Mar 15, 2011 5:54 pm
by Ready2plugin
Okay, now work your magic and double the speed to 6.6!

Re: A peek at the Leaf's Charger

Posted: Tue Mar 15, 2011 6:00 pm
by JimK
Here you can see they added in an EMI filter. This is not shown in the service manual. The wiring from the front of the car appears to be about 12awg. The 2 small black wires are the pilot signal from the EVSE and the handle interlock.
12 gage wires are bad news for a future 6.6kw charger upgrade! A wiring harness upgrade will certainly drive the cost up

Re: A peek at the Leaf's Charger

Posted: Tue Mar 15, 2011 6:07 pm
by Ingineer
My take is that the 6.6kW upgrade would be tricky. First off, it would require 2 beefier wiring harnesses, both running the length of the car; one from the J1772 inlet to the charger (EMI filter) and one from the charger to the HV junction box. The reason is the size of these wires appears to too small to support anything larger. It might also require an upgrade to the J1772 inlet itself.

It would also require draining the cooling system and crawling under the car to disconnect the lines.

-Phil

Re: A peek at the Leaf's Charger

Posted: Tue Mar 15, 2011 6:15 pm
by palmermd
Ingineer wrote:My take is that the 6.6kW upgrade would be tricky. First off, it would require 2 beefier wiring harnesses, both running the length of the car; one from the J1772 inlet to the charger (EMI filter) and one from the charger to the HV junction box. The reason is the size of these wires appears to too small to support anything larger. It might also require an upgrade to the J1772 inlet itself.

It would also require draining the cooling system and crawling under the car to disconnect the lines.

-Phil

What VIN are you looking at? Is is preproduction or consumer? I'd be curious to see if there is larger wires in some of the most current deliveries now that they know they have to upgrade the charger.

Re: A peek at the Leaf's Charger

Posted: Tue Mar 15, 2011 6:21 pm
by KeiJidosha
Ingineer wrote:My take is that the 6.6kW upgrade would be tricky. First off, it would require 2 beefier wiring harnesses, both running the length of the car; one from the J1772 inlet to the charger (EMI filter) and one from the charger to the HV junction box. The reason is the size of these wires appears to too small to support anything larger. It might also require an upgrade to the J1772 inlet itself.

It would also require draining the cooling system and crawling under the car to disconnect the lines.

-Phil
I think that’s why Nissan doesn’t want to talk about a 6.6kW upgrade. It is too integrated into the design to do profitably. Throw this thing away and buy a new one. New harness, new EMI Filter, change software, teach it how to read the pilot signal. Software update to the car and carwings. Is the cooling sufficient? And dealer Labor for doing all this. You'd faint when they show you the quote.

Huge mistake not to go 6.6kW fromt he start.