EV Charge Controller Manual
Contents
1. The figure below shows the Cell Loop and Buzzer connections pf A fT BO c Et 1 8 ChameStar Extra a R ENT CANL PSelect o EVSEDisc reserved Proximity Figure 8 Cell Loop and Buzzer Connections Driveaway Protection Driveaway Protection is a failsafe mechanism that prevents the EV being driven if the charger plug is connected This feature is implemented by signal EVSEDisc E3 This is an open collector signal to ground fused to 200ma The signal is open if the J1772 cable is plugged in or if the EVCC is not powered Conversely the EVSEDisc input is switched to ground if the EVCC is powered up and the cable is not plugged in How to disable the EV from driving is up to the discretion EV designer These contacts could be wired into the control logic of the primary contactor Note The EVSEDisc contacts may not be suitable for directly control of a primary contactor A typical primary contactor requires 1A or more of holding current which is well above the 200ma fused limit EVCC v2 3 Apr 2015 The figure below shows the connections used for Driveaway Protection ee E F ee a HotInRun J1772Pilot CellLoop2 end CAML CANL PSelect a ite Buzzer reserved Proximity Figure 9 Driveaway Protection Connections Profile Selection Up to four charging profiles may be defined with the EVCC numbered from 1 to 4 Each profile contains a complete copy of all charging parameters2. Step 2 Plug in the USB to serial port cable If the drivers are correctly installed the host computer will recognize the new virtual serial port device to use this device is necessary to determine the virtual serial port device name e The virtual serial port device name is of the form COM lt n gt where n is a small number This number can be determined by looking at Control Panel gt System gt Device Manager gt Ports In the example below it is COM15 i E Control Panel Tew Favorites Tools Help ay Free Space Comments Deak EJ wi Search Folders X i gt 2 System Properties 2 x Address E Control Panel System Restore Automatic Updates se General Computer Name ardware Control Panel Accessibility Add Hardware ES Switch to Category View Options Device Manager The Device Manage lists all the hardware devices installed EH ia s on your computer Use the Device Manager to change the properties of any devide See Also Folder Options Fonts Device Manager ra amp Windows Update CT 4 Device Manager Ego Disk drives E Display adapters 2 DYD CD ROM drives 53 IDE ATA ATAPI controllers amp IEEE 1394 Bus host controllers 5 gt Keyboards 15 Mice and other pointing devices Modems Monitors ES Network adapters Pe E PCMCIS adapte
3. or absorption charge phase The EVCC will only enter the finishing charge phase if the bulk charging phase completes successfully if termc is reached In particular if the bulk charge phase terminates because of a charging timeout termt then this 1s considered an abnormal termination For its cells Trojan recommends a maximum voltage of 2 45 to 2 79v per cell and a current limit of 1 3 of C29 This phase completes when the charging voltage rises to the target finishing voltage In the example of twelve 30XHS cells here are suggested EVCC settings e fin maxv 187 2 The finishing voltage would be 2 6v 6 cells 12 batteries 187 2v e fin maxc 2 6 Note that this is the same as the termc setting above e fin termt 480 2 hours termt is a failsafe on this charging phase Float Charge Once Lead Acid batteries are charged they may be kept on a float charge or trickle charge Lead Acid batteries have a relatively high self discharge rate and this phase keeps them topped up if the EV sits for an extended period of nonuse For its cells Trojan recommends a float voltage of 2 2v per cell A current limit is not explicitly specified In the example of twelve 30XHS cells here are suggested EVCC settings e flit maxv 158 4 The float voltage would be 2 2v 6 cells 12 batteries 158 4v e flt maxc 2 6 Note that this is the same as the termc setting above e flt termt 0 No timeout Limitations The EVCC does n
4. 7 For debugging use trace state to verify that the EVCC attempts to start charging if the J1772 plug is in and the user powers up the EVCC Verify Charger and CAN 1 Connect Charger to J1772 connect CAN between Charger and EVCC 2 Verify proper installation of the CAN termination resistors Measure between CANH and CANL to verify that the resistance of 600hms Remember that if the internal EVCC termination resistor is used that it must be powered up in order to make this measurement 3 Now verify that when a charge cycle is started that messages are exchanged between EVCC and Charger Use trace charger or trace can to log the messages 4 Ifthe pack is not yet connected to the Charger the charge cycle will stop after a minute Systems Test 1 Verify all systems functions 19 EVCC v2 3 Apr 2015 Command Line Interface Startup Banner When the EVCC is powered up it will print the following KKEKKKKKKKRKKKKKKKKKKKKKRKKKKRKKKKKKKKKRKKKKRKKKKRKKKKKKKKKEKKK s EV Charger Controller v2 3 0 K ai Thunderstruck Motors Dilithium Design ai Do RR RA RR ARR RAR ARR ARR RR AR ARR AR ARR RR AR ARR RK RR R RR RR RR RD evcc gt help The help command prints out command help evcc gt help SHow lt gt Version Config History lt gt Status version firmware version config g nfig ration HLStory charge history SEt lt gt BMS CHARGER CHARGER2 CHARGER3 CHARGER4 PROfile MAP EX
5. a Ane lane Tatoos cno om PSelect sida Buzzer EVSEDisc reserved Proximity Figure 12 CAN Connections To simplify CAN network wiring the EVCC contains an internal configurable CAN termination resistor By default this termination is enabled When the EVCC is used as an intermediate node the termination resistor may be disabled by using the CLI command set cantermdis When installing the CAN network keep in mind that some CAN devices contain an internal termination resistor and must be installed at the end of the CAN string In order to verify the proper CAN terminations make all connections 10 EVCC v2 3 Apr 2015 and measure the resistance between CANH and CANL The resistance between CANH and CANL should be 60ohms which indicates the presence of two 120ohm resistors in parallel Note that the internal EVCC termination resistor is not bridged onto the CAN network unless the EVCC is powered up This design choice will cover the vast majority of installation scenarios However there is one case where this may not be acceptable namely when 1 the EVCC is a terminal node and 2 the CAN network is active by other devices and the EVCC is powered down In this rare case the recommendation is to disable the termination resistor in the EVCC and connect a physical resistor instead CAN Protocol The EVCC supports a single CAN interface which runs at 250Kbs and uses 29 bit Extended Identifiers These para
6. cell loop t im i ie a a Gora emp Ket IP ep TIE mp my im a E su SE ie fere Te h e ETE ere le ew ake Wie e q Te fre kr BREET EV Charger Controller PACK Figure 1 EVCC System Diagram The EVCC draws negligible current less than 0 1 mA when off When charging the EVCC is started by a momentary pushbutton and turns itself off when the charge cycle is completed The EVCC is configured using a simple serial interface This interface is used for configuration and debugging but is not required for normal operation Diagnostic commands are supported to verify proper wiring to trace CANBUS messages and to retrieve charging history The EVCC supports the SAE J1772 standard J1772 defines the physical connector and protocols used between the charging station known as the Electric Vehicle Service Equipment and the Electric Vehicle The J1772 Proximity signal is used to determine if the charger plug is present The J1772 Pilot signal is used to start and stop charging by enabling and disabling the contactor in the EVSE The J1772 Pilot duty cycle is measured and can be used to limit charging current Driveaway protection is supported so that the EV cannot be driven if the charge cable is still plugged in EVCC v2 3 Apr 2015 The EVCC supports TSM2500 and ELCON CAN enabled chargers Charge voltage charge current and overall charge time are controlled completely by the EVCC over the CAN
7. By default Profile 1 is created and is used by default A new profile may be defined using the set profile command and then editing the charge parameters such as maximum charging voltage and maximum charging current associated with that profile When charging a profile is selected using the Pselect input B3 The EVCC measures the resistance to GND at this input and deduces four possible selections inf 20K 5K and 0 If the PSelect input is left unconnected it will read open or infinite resistance to ground and would map to inf If the Pselect input is shorted to ground it will measure 0 Finally if a resistor is connected between the Pselect input and ground the remaining two choices 20K and 5K can be selected The EV designer may decide to leave this feature unused connect the input to a switch to GND to enable two profiles or connect it to a multi position switch and a resistor network and enable up to four profiles In operation these four inputs represent a switch setting and not a profile number The mapping from setting to profile number is done using the profile map See the command set map So for example inf might be mapped to Profile 1 and 0 might be mapped to Profile 2 Tatoo TE TES rr oreeson Eara 2 HotinRun J1772Pilot CellLoop2 CANL GND J1772 Buzzer EVSEDisc reserved Proximity Figure 10 Profile Select
8. In this case the user specifies available line current to be J1772 and specifies the line voltage This case is similar to the previous however the line voltage is now known ChargeCurrent linev J1772DutyCycle 6 9 maxv As a final comment note that the power capability of the charger is not configured in the EVCC In practice if the requested power is more than what the charger can deliver charger firmware will reduce the delivered current in order to stay within its power limits Example Let s suppose a user wants to use different EVSE charging stations a primary EVSE at home capable of 220V at 30A a secondary EVSE capable of 110V at 15A and also wants the ability to do J1772 opportunity charging in general This could be configured in the EVSE with three charge profiles 1 Primary EVSE Define maxv linev 220 linec 30 In this case the EVCC will compute the charge current Alternately the user could define maxv and maxc directly or could use profile 3 below 2 Secondary EVSE Define maxv linev 110 linec 15 3 Opportunity Charging Define maxv linec J1772 Determining Charge Parameters for Sealed Lead Acid Batteries The EVCC supports a three phase charging algorithm to charge SLA batteries The first phase the bulk phase is used by both Lithium and SLA batteries The remaining phases finishing and float have target voltage and current limits fin maxv fin maxc flt maxv flt max
9. time hours voltage current current last EVSE disc 1 mins 7Wh 148 9V 7 9A 7 9A e normal 214 mins SZ49Wh 152 9V 7 9A 0 5A 2 EVSE disc 1 mins OWh 144 8V 0 0A 0 0A 3 comm err O mins OWh 0 0V 0 0A 0 0A evcc gt The full set of term reason codes is e EVSE disc J1772 charge plug became unlocked while charging 93 EVCC v2 3 e cell loop acell loop fault or HVC condition was detected comm err communications error with the charger e pack disc no pack was detected e timeout the maximum charge time was reached e normal normal completion charge current is less than terminating charging current e fintimeout finishing charge timeout e fin normal normal termination of finishing charge e flttimeout float charge timeout Apr 2015 When multiple chargers are configured the format of the charge history is modified to show the contribution of each charger evcc gt show history term charge watt maximum maximum num reason time charger hours voltage current last EVSE disc 2 mins tsm2500 6Wh 127 8V 2 2A sm2500 _ 42 6Wh 127 5V 2 0A TOTAL LZ2Wh 12726V 4 2A set This command sets the configurable parameters For voltage and current whole numbers 145 or decimal numbers 145 2 can be entered The EVCC supports one decimal digit of precision set lt gt Using the set with no parameters will option
10. 42 VSL Tsay AS Jey WHioU WDS Uso U0S10730 0 Eom2500 42 V 127 2 AS O29 WH lo0 Wh 0 40 OOTLUT S00 Esmz500 422 V l2loer A 3497 W190 Wh 0 47 JOTO S024 Usmz500 4239 V 127 24 B 29 W 190 Whe 0 43 OO LO02 30 5 temzo0U 422 V lZlve A 3x97 N 750 Wh 0 44 34 EVCC v2 3 Apr 2015 Integration with CAN Enabled BMS The EVCC can be used with a CAN enabled Battery Management System The following functions are supported e High Voltage Cutoff HVC Detection In this case the BMS detects that at least one cell has exceeded its programmed High Voltage Cutoff limit If this occurs the BMS sends a message to the EVCC which causes the EVCC to stop charging e Balance Voltage Cutoff BVC Detection In this case the BMS detects that at least one cell has exceeded its programmed Balance Cutoff limit If this occurs the BMS sends a message to the EVCC that it should reduce its charging current to the maximum balancing current maxbc Lowering the charging current allows current cell balancers to prevent additional charging of the highest cells in the pack e Low Voltage Cutoff LVC Detection In this case the BMS detects that at least one cell voltage is less than its programmed Low Voltage Cutoff limit If this occurs the BMS sends a message to the EVCC which causes the EVCC to operate the buzzer BMS Operation The programming of the actual HVC BVC and LVC are done in the BMS The BMS must determine if any cell in the pack meets these co
11. EV chassis ground For more information on J1772 see http en wikipedia org wiki SAE J1772 and https code google com p open evse wiki J1772Basics Wiring Without J1772 Although J1772 is recommended its use is optional When using J1772 the EVCC J1772 Proximity signal is connected to ground through a 150 ohm resistor built into the J1772 charge plug This indicates that the charge plug has been plugged in and is locked When J1772 is not being used the EVCC J1772 Proximity must either be connected directly or through a switch to GND to allow charging Here are two wiring options that do not use J1772 Option retains most EVCC functionality e Wire J1772 Proximity to GND through a switch the charger present switch To charge plug in the charger close the charger present switch and press ChargeStart Charging operates as designed and the EVCC turns itself off when complete The EVCC Drive mode operates as designed HotInRun enables the EVCC the cell loop operates the buzzer If driveaway protection is implemented the charger present switch must be turned OFF in order to operate the EV Option 2 is used when the EVCC is only used for charging e Wire J1772 Proximity directly to GND Do not wire Charge Start To charge plug in the charger and apply 12V to HotInRun The EVCC will power up and begin charging When the EVCC completes charging it will stop sending CAN messages to the charger bu
12. F Ports COM amp LPT Communications Port COM1 AB X IDE ThunderStruck 7 USB Serial Port COM15 9 Help and Support A va Tan i ES File Action view Help F Mouse Network N DE m8 2e mA Connections R k iv Batteries i E g Biometric F Printers and Regionaland Hardy ER Bluetooth Faxes Language 7 Computer a EKSI Continue Open Off A E 2 E lig Motors Ele Step 3 Install a terminal console program e g a telnet client on the host computer 14 EVCC v2 3 Apr 2015 There are many suitable telnet clients that may be used For Windows and linux one popular choice is PuTTY available for download at http www chiark greenend org uk sgtatham putty download html Step 4 Configure the telnet client for use The first time PuTTY is opened it will present the following Features E Window Appearance Behaviour Translation Click on Serial in the Category column Verify that the Speed is 9600 8 data bits 1 stop bit Enter the Serial Line to connect to in this case COM15 i Features EF Window XONZ XOFF Do not hit Open just yet Go back to Session by clicking the word Session in the Category window 15 EVCC v2 3 XS PuTTY Configuration gt Logging El Terminal Appearance Behaviour i Translation Selection evd Jo o CO
13. charger in the EVCC to perform this test 18 EVCC v2 3 Apr 2015 Bringup Checklist and Troubleshooting Hints EV Installation 1 Connect B GND HotInRun 2 Connect J1772 Proximity J1772 Pilot J1772 GND 3 Connect PSelect to a selector switch and resistor array if used Verify Analog Inputs 1 Type measure with no parameters to get the expected readings for each analog input Note that if there is not a good ground connection between J1772 ground and EV chassis ground that the J1772 readings will be erratic 2 Verify Cell Loop using measure loop a Disconnect J1772 plug if connected b Verify readings with cell loop open and closed 3 Verify J1772 Proximity using measure proximity a Disconnect cell loop if connected b Verify readings with charger plug disconnected connected and unlocked 4 Verify Cutback if used using measure pselect a Verify readings with different pselect switch settings Verify Charge Start and J1772 1 Connect Cell Loop to CellLoop1 and CellLoop2 2 Plug in J1772 Plug 3 Apply 12V to HotInRun The EVCC should start charging LED blinks once per second and the relay in the EVSE should operate after a short delay 4 Assuming the CAN bus is not connected to the charger yet the charge cycle should stop after 10 15 seconds 5 Remove 12V from HotInRun the EVCC should lose power LED goes off 6 Ground ChargeStart The EVCC should power up and go into Charge state
14. interface to the charger A constant current constant voltage charge curve is supported for Lithium Batteries and a three phase charge cycle is supported for Lead Acid Batteries The EVCC will stop charging if the J1772 plug becomes unplugged a cell overvoltage error occurs there is loss of communication between the EVCC and Charger or the maximum configured charge time is reached Charging also stops at the end of a normal charge cycle which for Lithium batteries occurs when the charging current drops below the minimum configured charge current Determining cell overvoltage errors and cell undervoltage error detection is the function of an EV Battery Management System BMS The EVCC can be configured to interface with a BMS either by a cell loop or by CAN messages or by both When a CAN BMS is used the EVCC can also be configured to handle balance cutoff which lowers the charging current when a cell exceeds a balancing threshold Charging history is provided for the last sixteen charge cycles and includes the reason that charging stopped total charge time maximum voltage maximum current final current and watt hours delivered The EVCC supports up to four parallel chargers for faster charging When multiple chargers are configured they are individually CAN addressed Work is divided evenly between the chargers and statistics are gathered and recorded on each charger individually When driving the EVCC 1s started by
15. reserve the right to make changes or improvements in design or manufacturing without assuming any obligation to change or improve products previously manufactured and or sold For general support and warrantee issues contact connect thunderstruck ev com For errors in this document or comments about the product contact djmdilithium gmail com Document History Rev 2 0 0 Sept 22 2014 In review Rev 2 0 1 Sept 30 2014 Production Version Rev 2 0 2 Nov 10 2014 Added Mac OSX serial support Rev 2 1 0 Feb 25 2015 Added support for v2 1 features including multiple chargers Lead Acid CAN BMS integration Cutback configuration was changed Rev 2 3 0 Apr 25 2015 Updates for EVCC 2 3 hardware Added profile support 43
16. stop the command by typing any character The measure command with no parameters will display the expected values of the A D inputs evcc gt measure This command repeatedly shows an analog input for 30 seconds Press any key to stop display The following values are expected loop Cell Loop A D V gt 253V OR proximity J1772 Proximity A D V gt 4 0V disconnected V gt 2 5V connected else locked pselect Profile Selection A D S EVCC v2 3 Apr 2015 R gt 30K inf 30K gt R gt LOK 20K 10K gt R gt 2K SK 2K gt R 0 evcc gt measure loop The measure loop command gives a real time measurement of the cell loop evcc gt measure loop evcc gt Loop A D 4 97V Loop A D 4 97V Loop A D 4 97V Loop A D 4 97V Loop A D 4 97V measure proximity The measure proximity command gives a real time measurement of the J1772 proximity input In the example given below both the measure proximity and trace state commands are enabled Initially the J1772 charge plug is connected then it becomes unlocked and then finally removed evcc gt me prox evcc gt Proximity A D 1 50V Proximity A D 1 50V Proximity A D 1 50V 00 06 07 5 old state CHARGING new state WARMDOWN j1772 WAITING FOR DISC term rsn EVSE UNLOCKED Proximity A D 2 76V Proximity A D 2 76V Proximity A D 4 45V 00 06 12 0 old state WARMDOWN new state WARMDOWN j1772 DISCONNECTED term rsn 0 Proximity A D 4 45V Proxim
17. the bms configuration is set to can instead of loop the output would be the following evcc gt set bms can evcc gt show state DRIVE can bms OK proximity EVSE not connected buzzer ON uptime 0 hour s 0 Minuce s 33 second s evcc gt show state CHARGE cell loop OK proximity EVSE Connected and locked buzzer OFF voltage 147 7V current De SA charger 306 msgs sent 320 msgs received uptime 0 hour s 3 minute s 30 second s show version The version command displays firmware version number and build date evcc gt show version version Veo U7 Apr 28 2015 14225717 evcc gt show config The show config command displays configuration parameters At its simplest the output of show config is the following evcc gt show config bms loop charger tsm2500 maxv gt 20 0V maxc gt 2 UR termc gt DMA termt 120 08 evee gt 21 EVCC v2 3 Apr 2015 The output of show config becomes progressively more complex as more features are enabled If only one charge profile is defined the full set of configured parameters is given below bms the bms type loop can or both charger the configured charger model e charger2 if configured model types of chargers2 e charger3 if configured model types of chargers3 e charger4 if configured model types of chargers4 e linev if configured line voltage of service connection e linec if configured li
18. the termination charging current in Amps If the current drops below this setpoint then the charging stops evcc gt set termc 5 set termt This sets the maximum charging time in hours evcc gt set termt 6 5 set fin_maxv set fin_maxc set fin_termt These commands are used to define the finishing charge phase voltage current and charge time for Sealed Lead Acid battery charging See below Finishing Charge for examples of use _2 8 EVCC v2 3 Apr 2015 set flt maxv set flt maxc set flt termt These commands are used to define the float charge phase voltage current and charge time for Sealed Lead Acid battery charging See below Float Charge for examples of use reset reset history The reset history command resets the charge history evcc gt reset history charge history has been reset evcc gt reset profile lt n gt The reset profile command can be used to delete Profiles 2 4 It is not possible to delete Profile 1 evcc gt reset profile 3 reset extindcharge The reset extindcharge command sets the ExtInd output back to default behavior e g ExtInd tracks the EVCC LED reset cantermdis The reset cantermdis command sets the CAN termination resistor back to default behavior e g connected trace The trace command enables various forms of message or state tracing These commands show a timestamp uptime and can be useful for logging or debugging CHARGER STATE and CANBUS tracing may be inde
19. 0 00 16 Rx CTS DSR GRI gt Note Although the operation of the serial port is very similar to the Windows examples above there is one important difference Windows keyboards generate an ASCI DEL character when a delete is pressed MAC keyboards generate an ASCII BS character Current EVCC firmware only interprets the DEL key and the MAC delete key may not work as expected However the ASCI DEL character can usually be generated by MAC keyboards look for another delete key with an x or try pressing FN DEL 42 EVCC v2 3 Apr 2015 Warrantee and Support The Thunderstruck return policy is available at http www thunderstruck ev com return policy html The EV Charger Controller is warranted to be free from defects in components and workmanship under normal use and service for a period of 1 year When failing to perform as specified during the warranty period we will undertake to repair or at our option replace this product at no charge to its owner provided the unit is returned undamaged and shipping prepaid to Thunderstruck motors The product is intended for non commercial use by hobbyists The warranty does not apply to defects arising from miswiring abuse or negligence accidents opening the enclosure or reverse engineering Thunderstruck Motors and Dilithium Design shall not be responsible for any incidental or consequential damages Thunderstruck Motors and Dilithium Design
20. 38 ff Uz 0leZiT 25 ESm2500 18eb2440 00 fc 4b 04 80 Oc 4a ff D020 132 748 evec 18e54024 fc es 00 ce Dc ft Li ff 00 01 27 9 tsm2500 41 18eb2441 01 fd 00 00 80 Oc 38 ff 00 01 27 9 tsm2500 gt 18eb2440 00 fc 4b 04 80 Oc 4a ff 0030 152653 evcc 18654024 fe cs DO 6c Dc fI f ff 00 01 28 4 tsm2500 41 18eb2441 01 fd 00 00 80 Oc 38 ff 002012238 5 52500 18eb2440 00 fc 4b 04 80 Oc 4a ff trace state The trace state command displays internal EVCC state transitions It shows whether the EVCC is in DRIVE CHARGE or CHARGE WARMDOWN as well as the state of the J1772 charge plug Here is an example of state trace output that shows the charger plug being plugged in and unplugged evcc gt trace state state tracing is now ON evcc gt 00 06 53 4 old state DRIVE new state CHARGE j1772 LOCKED term rsn 0 00 07 16 9 old state CHARGE new state CHARGE WARMDOWN 31772 WAITING FOR DISC term rsn EVSE UNLOCKED OO20 7 S17 2 old state CHARGE WARMDOWN new state CHARGE WARMDOWN 31772 DISCONNECTED term rsn 0 00 07 28 9 old state CHARGE WARMDOWN new state DRIVE j1772 DISCONNECTED term rsn 0 trace off The trace off command turns off all tracing evcc gt tr off all tracing is now OFF measure The measure command is used to verify the A D inputs When this command is issued the EVCC will repeatedly measure and print the value of an analog input The command will run for 30 seconds and then automatically turn itself off Alternately the user can
21. 772 charge plug is disconnected connected or locked When the J1772 charge plug is fully inserted it is locked When the charger release button is pressed by thumb on the charger plug the charge plug becomes unlocked or simply connected Should the plug become unlocked while charging charging will immediately stop EVCC v2 3 Apr 2015 The J1772 Pilot signal C2 allows the EVSE to advertise how much power is available for charging and it allows the EV to control when to start and stop charging The EVCC determines how much power is available by measuring the duty cycle of the J1772 Pilot square wave This is used along with other configured information in the EVCC to determine the actual charging current The EVCC controls when to start and stop charging by switching an appropriate diode and resistor between the J1772 Pilot signal to GND The EVSE monitors J1772 Pilot and only connects mains power if requested to do so The figure below shows the J1772 connections cle TE lt ipo TES Te ores Eara 2 MotinRun GND HERRE PRACA RES Figure 7 J1772 Connections Note It is important to insure that there be a good ground connection between the J1772 Ground and both the EV chassis EVCC GND This is required in order that the J1772 Pilot and J1772 Proximity signals work correctly One way to insure that is to make sure that the charger enclosure itself has a good connection to
22. MI5 00000 0 0o o c o o 5 Window Lf Raw Telnet Rlogin SSH o Colours i i Derauii Settings El Connection Apr 2015 Set the Connection type to Serial Give the new session a name in this case EVCC in the Saved Sessions window and press Save to save the session PuTTY is now configured Step 4 Open the comm port Select the saved session EVCC and click Open Logging i Terminal E Window i Appearance Behaviour Translation Selection Colours E Connection A screen like the following should appear 16 EVCC v2 3 Apr 2015 COM15 PuTTY Step 5 Connect the serial cable to the EVCC Apply power to the EVCC by providing a 12V supply to B and GND Connect 12V to HotInRun The EVCC LED should start blinking assuming the cell loop has not been hooked up yet and the following banner should be displayed EY Charger Controller v2 0 Thunderstruck Motors Dilithium Design Step 6 At this point the EVCC may be configured Configuration is stored in non volatile memory and retained across a power cycle See below Command Line Interface for details on what commands are supported and their Syntax The EVCC is supplied with defaults but at the very minimum it will be necessary to set the Maximum Charging Voltage using the command set maxv and Maximum Charging Current using the command set maxc
23. ON and one TSM2500 at the same time The following example defines a single charger and sets its model to tsm2500 evcc gt set charger tsm2500 evcc gt show config bms loop charger tsm2500 maxv 158 0V maxc 12 0A termc 0 5A termt FRA UDE evcc gt This example defines a second charger and sets its model to tsm2500 42 evcc gt set charger2 tsm2500 42 evcc gt show config bms loop charger ESmZ500 Charger tsmZ500 42 maxv Log OV maxc 12 0A termc 0 5A termt DA Or UE evcc gt A charger can be deleted by setting the model to none evcc gt set charger2 none Programming a TSM2500 Charger This section describes how to set the CAN addresses of a tsm2500 charger For this procedure the charger can either be directly connected to mains power or can be installed in the vehicle and the J1772 charge plug can be used to supply line power When doing this procedure insure that only one charger can receive line power In this example we want to define a second charger as model tsm2500 42 If the charger is already programmed as model tsm2500 42 then it would only be necessary to use the command set charger2 tsm2500 42 In order to program the charger it is necessary to use the program keyword To do this power up the EVCC by keyswitch Then type the following command evcc gt set charger2 tsm2500 42 program The EVCC will then print 33 EVCC v2 3 Apr 2015 KK ARA tsm2500 PROGRAMMING EA WARNING Thi
24. TINDCHARGE CANTERMDIS LINEV LINEC MAXV MAXC MAXBC TERMC TERMT FIN MAXV FIN MAXC FIN TERMT FELT MAXV FLY MAXC Fi TERMI REset History PROFILE EXTINDCHARGE CANTERDIS history reset charge history profile lt n gt deletes a charge profile extindcharge reset EXTIND to default EVCC LED cantermdis resets CAN termination to default enabled TRace CHarger CANbus STate OFF lt gt trace toggle ON OFF charger trace charger messages canbus trace canbus messages State trace EVCC state changes off disable all tracing MEasure lt gt LOOP PROXimity PSELect lt gt measure help loop measure Cell Loop A D proximity measure J1772 Proximity A D pselect measure PSelect A D In most cases either a full version or an abbreviated version of a command or command parameter can be used This is Shown in the help with the use of uppercase and lowercase letters For example the abbreviation for show is sh and the abbreviation for show configis sh c show The show command displays configured parameters or status If show is entered without parameters current status will be displayed 20 EVCC v2 3 Apr 2015 In the Drive mode the EVCC monitors the cell loop and operates the buzzer when the cell loop indicates a pack fault evcc gt show state DRIVE cell loop OK proximity EVSE not connected buzzer OFF uptime O hour s O minute s 33 second s If instead
25. Thunderstruck Motors EV Charger Controller v2 3 O 2015 Dilithium Design EVCC v2 3 Apr 2015 Contents OOS ss O E E E EA T A A 3 Installation and Theory oy FODER HON 25 uroen nende n a ee E eee ere ee 5 IVE CANO A ESS A E A E N E A SA 5 TOME LEE E E ee a E E E E E E Tr eee nore 5 IE E I E NAA EE S AT A A T A E E RR E TE RD ER 6 C UEG EB ERE A EE A AA EEA ONNE ar TO AT NENNE 8 Diven ay POCOO raa aE E E E E ee E EE eee 8 PPO VC HEE SE E E NE E E E 9 CANDO ps css sas E A A a EEEE E A E EA NE 10 EED ODE ON ore AE N EAA E AEE A E T 12 Ba aa E O e O AT EEE E EE 12 oaral abt AN ad ice dons sida SOS a oss N AGO N ba a E e ias 14 Sa E ES SEE A E T E E AANA T A E E A AAY 14 CDa O A A EAA EEA ETEA NAT ENE AE EEEO T EA NONE 18 Bringup Checklist and Troubleshooting Hints ccccccccccccsssssseeceecceeeeceassseeecccceeeeeeaaesseeceecceeeessaeaaeeeeceeeeeeeeaaaneseees 19 Command Gino E aa E E E led pene E E E E A EEA a 20 O BUE E A E E E EN E A A EA E AE A E olen ecieeeec ee 20 PS ie AEE ETEEN E EE El E 20 NINA ais SS o 20 CO o a dp T T E E E E E E E ETE 24 EET O E II E E E A N EE EE N E E E 29 O e E E A E DE 30 Configuring the EVCC with Multiple Chargers cccccccccccessssseeccccceeecesesececeeecceeesaaaaseeseeecceeeeeseaesseeeeeceeeeesauaaaneeeeeeeeees 32 SP OW ES ER EET ES E E A 32 CAN ne and Ade oode E AE DE ED re se eler ledelsens 32 EVCC CONTO Og sarc E EAEE EE EE ENES nos vats ee EET ad 33 Prostaminime a TOM2300 Caro ci aora
26. WARNING Lithium batteries can be dangerous if overcharged and it is strongly recommended that the user check with their battery supplier to determine appropriate charging parameters A bringup checklist is provided below The EVCC also has several diagnostic commands that can be used to verify proper wiring measure to trace can messages trace can to trace EVCC internal state changes trace state and to trace charger operation trace charger 17 EVCC v2 3 Apr 2015 Charger Support This section gives details on which charger models are supported by the EVCC TSM2500 See TSM2500 Series High Efficiency Intelligent Charger ThunderStruck User Manual Ver 1 0 2 http www thunderstruck ev com images ThunderStruckTSM2500Manual1 02 pdf The CAN connections are found on the four pin connector J3 CANL is pin 8 wired with a blue wire and CANH is pin 9 wired with a green wire No other connections are required on J3 The TSM2500 charger does not have an integrated termination resistor It is configured with a default CAN address however the CAN address can be reprogrammed The procedure to program the addresses is described below Programming a TSM2500 Charger Note that address programming may have been done at Thunderstruck as part of the order TSM2500 Charger Models Each charger requires a unique CAN address In EVCC terminology a charger model refers to both the manufacturer and its unique CAN
27. address The EVCC defines the following TSM2500 charger models e tsm2500 default e tsm2500 41 e tsm2500 42 e tsm2500 43 The default value for tsm2500 chargers is 40 Which is to say the EVCC uses the CAN address 0x18e54024 for messages TO the charger and 0x18eb2440 FROM the charger to the EVCC ELCON ELCON chargers must programmed with the CAN option In addition an external ELCON provided CAN module is needed that terminates the CAN and communicates to the charger over a serial interface Only two pins are provided for the CAN connection CANH and CANL The ELCON CAN module does NOT contain an integrated termination resistor ELCON Charger Models The CAN addresses of the ELCON chargers are determined by the outboard serial to CAN converter In order to change the CAN address a different serial to CAN module is needed The EVCC supports the following ELCON charger models elcon default e elcon e7 e elcon e8 elcon e9 The default value for ELCON chargers is E5 Which is to say the EVCC uses the CAN address 1806e5f4 for messages TO the charger and 18ff50e5 FROM the charger to the EVCC Determining the CAN addresses of a Charger If it is necessary to determine the CAN ID of a charger then power up the chargers individually and use the debugging command trace can messages to determine what IDs are being used The chargers will transmit these messages spontaneously and it is not necessary to configure the
28. atus is taken from the BMS EVCC STATUS IND message Note that the message also supports the BVC condition which the loop does not If that is reported then add EVCC v2 3 Apr 2015 the EVCC will drop back into balance cutback If there is a message timeout and BMS EVCC STATUS IND does not arrive then this is treated as a pack error e g HVC and LVC are assumed If both loop and can are configured then an error results if either input reports an error So in this case charging will stop if the loop opens the CAN message indicates HVC or there is a CAN message timeout Charging Lead Acid Batteries Lead Acid Batteries require a multi stage charging algorithm The terminology to describe the algorithms varies in the industry and between manufacturers Here we follow the documentation and requirements from Trojan See http www trojanbattery com pdf TRJNO109 UsersGuide pdf As an example consider a EV pack that consists of 12 Trojan 30XHS deep cycle flooded batteries charging at 25 C 77 F See the following from http www trojanbattery com pdf TRJNO111 ProdSpecGuide pdf For reference the C rating of 30XHS batteries is 130AH this number comes in handy below Diagram 4 Recommended Deep Cycle Flooded Wet Charging Profile Voltage Current per cell Amps Charge Current i 10 13 C 2 45V to 2 79V i 25 C 77 F 2 35V to 2 45V 25 C 77 F Charge Voltage DS 1 3 C 20 90 100 State
29. c The discussion above about voltage and current calculation applies equally to these two additional SLA charging phases simply replace xxx maxv and xxx maxc for maxv and maxc 13 EVCC v2 3 Apr 2015 Configuration Serial Port This section describes how to install the serial port drivers and establish serial communications from a host computer and the EVCC To use the serial cable a Virtual Comm Port driver VCP driver and a terminal application or telnet client is required Using a USB to serial bridge is a generic and popular way to connect a host computer to a microcontroller and the steps are basically the same regardless of the host computer and operating system Installation instructions are given below for Windows XP See Mac OSX Support below for instructions on how to enable the serial port on a MAC OSX machine Note that there are good tutorials on how to install the necessary drivers and application software available on the Internet for other versions of Windows MAC Linux etc Search for ftdi installation putty installation etc Step 1 Install the Virtual Comm Port VCP driver on the host computer The VCP driver is software on the host computer that emulates a serial port on top of a USB connection e VCP drivers are available at www ftdichip com Drivers VCP htm e Installation documentation is available at www ftdichip com Support Documents InstallGuides htm
30. charge termination Timeout U no Timeout set bms This sets the BMS type The EVCC can use a cell loop and or up to four CAN BMSs The BMS determines whether a cell in the pack has exceeded the High Voltage Cutoff Low Voltage Cutoff or Balance Voltage Cutoff Multiple BMSs cabe bve The following example just sets the bms type to be the cell loop evcc gt set bms loop The next example sets the bms to use CAN messaging evcc gt set bms can The next example sets the bms to use both cell loop and CAN messaging evcc gt set bms loop can set charger lt n gt This sets the charger type The first charger is named charger Chargers 2 through 4 are named charger2 charger3 charger4 The following command sets a single charger evcc gt set charger tsm2500 The following command sets a second charger evcc gt set charger2 tsm2500 42 set profile lt n gt This command selects a profile for editing There are four possible profiles 1 4 Initially only profile 1 is defined it is the default profile and cannot be deleted If the user types set profile lt n gt then this will both select a profile for editing and create the profile if it does not already exist Once a profile is selcted then subsequent editing commands e g set maxv etc apply to the parameters associated with the profile Profiles 2 4 may be deleted using the command reset profile lt n gt Examples of creating and editing p
31. es a unique CAN ID e EVCC configuration Each charger must be explicitly configured in the EVCC Line Power The EVCC assumes that the service can provide 220V at 30A Note that the cutback feature if enabled will limit line voltage and current to configured limits Power calculations are needed to make sure that there is sufficient power available to power all chargers A 220V 30A circuit has 6600Watts available Two 2 5Kw chargers running at full power can be placed on the line but three chargers cannot In contrast a 110V 15A circuit only has 1650Watts available CAN Wiring and Addressing See the section on CANBUS above for general guidelines When installing multiple chargers care must be taken that termination resistors are properly placed Keep in mind that some chargers have a termination resistor installed in the charger and so that charger must be at the end of the CAN string a EVCC v2 3 Apr 2015 Each charger must have a unique CAN address See Charger Support for information on how to determine the charger CAN address and change it if necessary EVCC Configuration The EVCC supports up to four chargers named charger charger2 charger3 and charger4 Chargers are defined in the EVCC using the set charger command When a charger is configured it is set to a charger model which indicates both the manufacturer and its CAN address It is possible to have chargers from multiple manufacturers e g one ELC
32. g To enable this option use the command DT EVCC v2 3 Apr 2015 evcc gt set extindcharge If this option is set this will be indicated in the show config output In order to disable this option and return the EVCC to default behavior use the reset extindcharge command set cantermdis The EVCC contains an integrated and programmable CAN termination resistor By default this termination resistor is connected to the CAN network In order to disable this termination resistor use the command evcc gt set cantermdis If this option is set this will be indicated in the show config output In order to disable this option and return the EVCC to default behavior use the reset cantermdis command set linev_cb set linec_cb This sets the maximum line voltage and line current available evcc gt set linev 110 evcc gt set linec 12 5 Note that the set linec command has j1772 as an option In this case the J1772 duty cycle will be used to determine available line current evcc gt set linec j1772 set maxv set maxc The command set maxv sets the maximum charging voltage in Volts The command set maxc sets the maximum charging current in Amps evcc gt set maxv 155 0 evcc gt set maxc 8 5 set maxbc This sets the maximum balancing charging current in Amps This option is only possible if a CAN BMS is used and it sends a BVC threshold exceeded indication to the EVCC evcc gt set maxbc 7 set termc This sets
33. gt is the specific serial number of the EVCC as discussed earlier gt Note The usbserial lt sn gt will not show up in the drop down menu if the USB is not plugged in prior to starting the program If this occurs exit CoolTerm plug in the USB cable and restart CoolTerm Serial Port Serial Port Options a Port Bluetooth Incoming Port gt Receive a RE Transmit Baudrate usbserial FTGDTRBM Miscellaneous Data Bits Parity none Stop Bits 1 Flow Control CTS DTR XON Initial Line States when Port opens DTR On DTR Off ORTS On RTS Off Re Scan Serial Ports 8 Still in Options go to the left hand column and click terminal Then change the window to match the settings below 40 EVCC v2 3 Apr 2015 Terminal Options Terminal em sem Terminal Mode O Raw Mode Transmit Line Mode Miscellaneous Reduce Refresh Rate _ Handle Bell Character Local Echo Replace TAB key with spaces No of spaces 4 ASCII View Options Cancel 9 Click Connect 090 CoolTerm 0 X l usbserial FTGDTR8M 9600 8 N 1 o TX Ww RATS 4 DTR t DCD Disconnected RX i CTS 4 DSR ty Al 10 Press the return key the EVCC command prompt should come up 41 EVCC v2 3 Apr 2015 090 CoolTerm O SB E x is New Open Save nne Disconnect Clear Data Options View Hex Help evcc gt usbserial FTGDTR8M 9600 8 N 1 Tx ATS DTR DCD Connected 0
34. ion Connections EVCC v2 3 Apr 2015 CANBUS CAN is a robust communications protocol designed for automotive applications CAN uses a two wire interface the signals are designated CANH CAN high and CANL CAN low Not shown but necessary is that each node on the CAN network must share a common ground e g chassis ground A CAN network is a daisy chain multistation network that must be terminated on both ends of the string by 120ohm termination resistors See below for a simple network diagram CANL Figure 11 CAN Network Diagram CAN wiring should be kept short and the conductors should be twisted Wiring stubs between the CAN network and the node should be kept as short as possible ideally less than a few inches Network wiring should be placed away from EMI ElectroMagnetic Interference such as the motor and controller and parallel runs next to EV traction cabling should be avoided In a simple installation there will be only two nodes on the CAN network the charger and the EVCC with a short and direct connection between the two In this simple case a short run of hand twisted wiring should work fine For longer runs more nodes or cases where EMI may be an issue shielded cable may be needed Ifa shielded cable is used the shield should be connected to chassis ground at a single place The figure below shows the connections used for CAN cla 2s jp TETE Tape foreso Ema censor ts O
35. ity A D 4 45V measure pselect The measure pselect command gives a real time measurement of the pselect input Note that this output is reported in resistance evcc gt me pselect evcc gt Pselect A D inf Pselect A D inf Pselect A D inf Pselect A D inf Pselect A D inf ae EVCC v2 3 Apr 2015 Configuring the EVCC with Multiple Chargers Up to four chargers can be used in parallel for faster charging A logical picture is shown in the diagram below J1772 CHARGER CHARGER2 Line Power canbus FC sm cm eo 120 Q 120Q optional e a he amp e 2 p 9o 9622 wees et o o a G 4 S f A p 2 ENEE si g gt dl S cell loop H e fe y a sas b PACK EV Charger Controller Figure 13 Multiple Chargers System Diagram Note that there 1s a single J1772 interface for line power which feeds all chargers The chargers are 1n parallel and they charge a single pack All chargers are placed on the CANBUS There is a single EVCC and it communicates with the chargers independently Also shown on the CANBUS 1s a CAN enabled BMS optionally present There are several design considerations when installing multiple chargers e Line power Two chargers require more power than a single charger One must verify that adequate line power is available e CAN wiring and addressing With more CAN nodes the CAN wiring is no longer simply point to point and installation must be done with care Each charger requir
36. lTermMac lt HE Dio Sy Be Q o Favorites E Macintosh HD amo L lt gt iCloud Drive TXT TXT AirDrop AppleScri EM Desktop FR Documents O Downloads H Movies J Music en Pictures rme CoolTerm app ReadMe txt CoolTerm Capture 2014 10 00 15 txt 38 EVCC v2 3 Apr 2015 4 Open the applications folder and double click CoolTerm app 090 Es Applications lt EJ m m amp Q Favorites E Macintosh HD A A A O iCloud Drive AirDrop App Store app Automator app Calculator app Calendar app Applications ES Desktop bi Documents lt amp Downloads Chess app Contacts app CoolTerm app Dashboard app Movies ig Music Pictures na Gr be Google Drive Dictionary app DVD Player app FaceTime app Font Book app 5 Click Options eee OBE E K R New Open Save Connect Disconnect Clear Data Bluetooth Incoming Port 9600 8 N 1 Ww TX Ww RTS W DTR DCD Disconnected RX Ww CTS t DSR amp Al 6 Ensure the baudrate is set to 9600 which should already be set by default 39 EVCC v2 3 Apr 2015 Serial Port Serial Port Options ceia Port Bluetooth Incoming Es gt Receive Transmit Miscellaneous Data Bits 8 A Parity none Stop Bits 1 Flow Control CTS DTR XON Initial Line States when Port opens O DTR On DTR Off ORTS On ORTS Off Re Scan Serial Ports 7 Click the drop down menu and select usbserial lt sn gt where lt sn
37. measurements into four possible choices as follows R gt 30K 30K gt R gt 10K 10K gt R gt 2K 20K gt R the result is inf the result is 20K the result is 5K the result is 0 Each possible result is mapped to a profile from 1 to 4 using the profile map Initially all four results select the default profile Profile 1 Suppose that we connect a switch to ground at the PSelect input and if the switch is closed we want to use Profile 2 Once Profile 2 is defined we can map 0 to Profile 2 by the command set map 0 2 The mapping is displayed using the command show config evcc gt set map 0 2 evcc gt show config bms loop charger tsm2500 profiles 1 oe 3 4 linec ILI IZ maxv 160 0V L150 20 maxc 15 0A 12 0A termc 0 2A 0 2A termt 120 UNE T U Ure profile map LE x 20K x SK X 0 x If a third profile were to be defined a switchable resistor would be required at the PSelect input The CLI command to enable the mapping from a 5K resistor to Profile 3 would be evcc gt set map SK 3 set extindcharge By default the ExtInd output follows the state of the EVCC LED The intention is that a 12V LED or bulb can provide a remote indication of the EVCC state by interpreting the EVCC blink patterns An option exists to instead configure this output to be 12V whenever the EVCC is charging This might be used for example to drive a relay or some other equipment in the EV when the EV is chargin
38. meters are not software configurable however both the TSM2500 and ELCON chargers require this rate The EVCC uses two types of messages to control a CAN enabled charger The first from EVCC to Charger provides the Charger with the desired values of charge voltage and charge current and the second message from Charger to EVCC that reports the actual Charging Voltage and Current This message may also report additional charger status EVCC Charger CAN messages are sent approximately twice a second both from EVCC to Charger and from Charger to EVCC If either the EVCC or the Charger does not receive these messages within a short time on the order of a few seconds charging will terminate EVCC BMS CAN messages communicate pack status such as Cell Undervoltage or Cell Overvoltage conditions These messages are used as an alternate to or conjunction with the cell loop to indicate pack fault conditions See 1 EVCC v2 3 Apr 2015 Integration with CAN Enabled BMS below for supported message definitions CAN Debugging CAN messages may be lost or corrupted as the result of EMI stubs that are too long or improperly terminated cables The CAN protocol has sophisticated error detection and recovery mechanisms that allow for automatic retry and recovery as well as ways of detecting and isolating misbehaving nodes In order to verify correct operation there are both high level tracing trace charger and a low level tracing trace ca
39. n facilities to show CAN message traffic LED Operation The EVCC LED has the following blink patterns Timeline seconds fo la lel 7 Ji bi fis TP solid ON fast blink 4x second ong ON short OFF a HERE Note that this blink pattern applies to the LED on the frontpanel of the EVCC enclosure as well as the ExtInd output e O O lx short blink 1 medium blink QIQ medium blink 1x second x short blink 1 medium blink 3x short blink 1 medium blink e There is an additional blink pattern when in the serial bootloader when waiting for a download image This is a very slow blink 1 blink every four seconds Charging This section describes the charging process in more detail Determining Charge Voltage and Charge Current The maximum charge voltage is specified by the EVCC parameter maxv This parameter must be configured by the user The maximum charge current can be determined by several methods described in more detail below Using maxc only The user can specify the maximum charge current explicitly maxc and set no other parameters In this case the EVCC will use maxc for the charge current ChargeCurrent maxc Note Using this approach the settings of maxv and maxe may draw more power than the service can actually provide and may trip a circuit breaker Set linev and linec do not configure maxc In this case the user specifies available line voltage and line cu
40. nditions and if so it sets a bit associated with each of these conditions This information is sent in a message from the BMS to the EVCC the message must be periodically sent at least once a second The EVCC supports 250Kbps CAN data rate and 29 bit identifiers r define uint8 unsigned char BMS gt EVCC message Identifier ny define BMS EVCC STATUS IND 0x01dd0001 define BMS EVCC CELL HVC FLAG 0x0 ser PE a cell as gt HVC 7 define BMS EVCC CELL BVC FLAG 0x02 set if a cell is gt BVC define BMS EVCC CELL LVC FLAG Ox04 JR Set il a cell is lt LVC 7 BMS gt EVCC message body ar typeder struct tBMS EVCC statusind uint8 bBMSStatusFlags see bit definitions above uint8 bReserved reserved set to 0 x tBMS EVCC StatusInd Note that although the CAN message only has a 2 byte message body up to 8 bytes may be sent to the EVCC These bytes should be set to 0 if so The EVCC will ignore additional message bytes EVCC Operation In order to use the CAN interface with the BMS it must be configured in the EVCC using the set bms command It is possible to configure the EVCC to only use loop only use can or use both loop and can If the EVCC is configured to only use loop then if the loop circuit is closed then the pack is error free if the loop circuit is open HVC is assumed if in CHARGE mode and LVC is assumed if in DRIVE mode If the EVCC is configured to use only can then the pack st
41. ne current of service connection maxv maximum charging voltage in Volts maxc maximum charging current in Amps lt maxbc if configured maximum balance current e terme terminating charging current in Amps e termt maximum charging time in minutes fin maxv 1f configured finishing charge voltage for SLA charging e fin maxc if configured finishing charge current for SLA charging e fin termt if configured finishing charge current for SLA charging E Ely maxv 1f configured float charge voltage for SLA charging amp flm maxe 1f configured float charge current for SLA charging e flin termt if configured float charge current for SLA charging options extindcharge if configured ExtInd tracks CHARGE state cantermdis if configured can termination resistor disabled An example of a full output with all options is shown below evcc gt show c bms loop charger tsm2500 chargerzZ 4 Esm2500 42 chargers amp Eem2500 4 charger4 elcon linev ALU HOV Lines i 3 Ohi maxv RR RS TS ERE BRS maxc 15 0A maxbe 1 2A terme Vez termt i E ORE fin MARY FOO SOV fin maxe i 2 0A RR MEE 218 Hear 4 0hr FLE Max Lo by fit maxe Dra LLE Forme Oe ora options extindcharge ExtInd is ON when charging gt cantermdis CAN termination resistor disabled Do EVCC v2 3 Apr 2015 If more than one charge profile is defined show config will display the fo
42. o start charging By momentarily grounding this input e g by a pushbutton switch the EVCC will power up and latch power on The EVCC automatically turns itself off when charging is complete 12V_Sw E1 is a switched output that can provide up to 200ma of current to downstream equipment when the EVCC is on ExtInd C1 is a 12V output that can drive an external indicator light or a relay By default this output tracks the EVCC LED However it is possible to configure this output to be ON whenever a charge cycle is in progress see set extindcharge The ExtInd output is protected by a 200ma resettable fuse The figure below shows the Power connections Tapete po fe fr oom ester fone BORRE OND 1772Pilot CellLoop2 BND CAN PSelect ee Buzzer EVSEDisc reserved Proximity Figure 5 Power Connections Note The design intent of ChargeStart and ExtInd is to connect to a momentary pushbutton and integrated 12V LED indicator near the J1772 charge port Charging is begun by plugging in the charger plug pushing the button and observing the light come on See EVCC System Diagram above J1772 The figure below shows the J1772 EV side connector and locations of the J1772 Proximity and J1772 Pilot signals These are connected directly to corresponding signals at the EVCC pilot proximity ground Figure 6 Face of J1772 Socket The J1772 Proximity signal C3 allows the EV and the EVSE to determine whether the J1
43. of Charge Note Charging time will vary depending on battery size charger output and depth of discharge Figure 14 Flooded Lead Acid Charging Profile Trojan Bulk Charge The first phase of charging is the Bulk Charge phase Note that the Bulk Charge phase is sometimes thought of as two phases a constant current phase and a constant voltage phase The EVCC supports this phase by the parameters maxv and maxc This phase is used by both Lithium and Lead Acid chemistries including flooded AGM and Gel See Figure 14 above For flooded cells the Bulk Charge phase brings the cells to over 90 state of charge For its cells Trojan recommends a maximum voltage of 2 35 to 2 45v per cell and a current of 10 13 Cyr The bulk charge phase completes when the charging current drops to 1 3 of C29 In the example of twelve 30XHS cells here are suggested EVCC settings e maxv 172 8 The charging voltage would be 2 4v 6 cells 12 batteries 172 8v e maxc 13 Since 30XHS cells have a Cr rating of 130AH the charging current would be 13A e termc 2 6 The guidelines are 1 3 of Cr 2 6A is 2 of the Ca rating of 30XHS e termt 480 10 hours This parameter is a failsafe the actual time of charge will depend on depth of discharge In 10 hours this would allow 13A 10H 130 AH to be delivered to the batteries 36 EVCC v2 3 Apr 2015 Finishing Charge For Lead Acid batteries the second phase of charging is the finishing charge
44. ot support equalization charge This type of charging purposely overchargers the batteries in order to balance the cells Higher charge cells bubble off excess charge as hydrogen gas and lower charged cells catch up Temperature sensors are not supported in the EVCC so the EVCC does not perform temperature compensated charging The examples assumes charging at a constant 25 C in a well ventilated area DISCLAIMER This is an example only These instructions do not cover all details or variations in the equipment and do not claim to provide for every possible contingency met in connection with installation operation or maintenance It 1s strongly recommended that the user check with their battery supplier to determine appropriate charging parameters a EVCC v2 3 Apr 2015 Mac OSX Driver Installation Before starting the procedure below ensure the 12V power is hooked up to EVCC B and GND and that 12V is connected to HotInRun Finally insure that the USB to serial cable is plugged into the computer For MAC OS X the virtual serial port device name is of the form usbserial lt sn gt where lt sn gt is the serial number of the USB to serial device An example of what the name of the EVCC would look like is the following usbserial FTGDTR8M The MAC OSX distribution includes the applications terminal and screen which may be used However we have found that CoolTerm 1s simpler to install and use CoolTerm 1
45. pendently enabled Trace configuration is stored in EEPROM and is present after reboot trace lt gt Trace with no parameters toggles state trace on and off trace charger The trace charger command displays messages from the charger This trace also shows the current number of charging watts and the accumulated WattHours of charge evcc gt trace charger charger tracing is now ON evcc gt 00 08 22 7 V 148 6 A 7 9 W 1173 Wh 0 96 00 08 23 1 V 148 6 A 7 9 W 1173 Wh 1 12 00 08 23 6 V 148 6 A 7 9 W 1173 Wh 1 28 00 08 24 1 V 148 6 A 7 9 W 1173 Wh 1 45 00 08 24 6 V 148 6 A 7 9 W 1173 Wh 1 61 00 08 25 1 V 148 6 A 7 9 W 1173 Wh 1 77 00 08 25 6 V 148 6 A 7 9 W 1173 Wh 1 93 00 08 26 1 V 148 6 A 7 9 W 1173 Wh 2 08 00 08 26 6 V 148 6 A 7 9 W 1173 Wh 2 25 00 08 27 1 V 148 6 A 7 9 W 1173 Wh 2 41 00 08 27 6 V 148 6 A 7 9 W 1173 Wh 2 57 00 08 28 0 V 148 6 A 7 9 W 1173 Wh 2 73 00 08 28 6 V 148 6 A 7 9 W 1173 Wh 2 89 00 08 29 0 V 148 6 A 7 9 W 1173 Wh 3 05 00 08 29 6 V 148 9 A 7 9 W 1176 Wh 3 22 29 EVCC v2 3 Apr 2015 trace canbus The trace canbus command displays canbus messages to and from the charger Each line gives a timestamp the originator of the message if known the CAN ID and CAN message contents in hexadecimal evcc gt trace can canbus tracing is now ON OOO Se a evecs 18654024 fc es 00 Go UG LE ff LI 00 01 27 4 tsm2500 41 18eb2441 01 fd 00 00 80 Oc
46. r iar DE DE TNE or err ae Onn er eee er ee re eee 33 Chare me wii Multiple CA OCS core roerne n EEE O aai 34 Integration wir CAN Enabled BMS 9 arrene EE EE TE NE 35 BM OD 2116 Oa A ERE N ENA RE REA O O E E eee EE 35 BY ODETI E A A T E AN A AAT A 35 Charme licad AL BEER SE E E O AA EEE O I E E O INE E E 36 PULCI O eee E E nee A T E ai E A 36 AE r a EEE E E EEE IEA PE A DER EAE N E E A EE EEA T 37 EVCC v2 3 Apr 2015 NG AU CA 27 a A Arcada 37 LABIOS tis ion EST uie Tose na db a ane Daca dd Dn 37 Nac se Bra aie salao nina Dando SENERE Rea TESS Pes emer nen ERE een GRENENE ad da E A 38 WV GET AMC era ds UD Ol eee En O because A O RE 43 Document HR COTY sara sara dps cs anna bee Re oan cao eases va unease Sosa eases RUC enn 43 _2 EVCC v2 3 Apr 2015 Overview The Electric Vehicle Charger Controller EVCC integrates charger CANBUS control and J1772 functions in a simple to use cost effective and environmentally robust enclosure Charge parameters such as maximum voltage maximum current and total charge time are configured saved in nonvolatile memory and used when charging to control a CAN enabled charger The EVCC connects to analog cell loop Battery Management Systems BMSs as well as CAN enabled BMSs momentary pushbutton i Charge Start SED Ground Extind Pselect profile AA on selection buzzer Ground J1772 Pilot HotinRun Driveaway protection E USB to serial cable
47. rofiles This 1s the default configuration evcc gt show config bms loop charger tsm2500 maxv E Z0c0M maxc 2 0A termc ia A termt T2720 20h 25 EVCC v2 3 evcc gt This command creates Profile 2 with default configuration evcc gt set profile 2 evcc gt show c bms i Loop charger tsm2500 profiles I oe 3 maxv EO ZOO ZO eM maxc i 2 0A 2 0A termc 0 2A 0 2A termt E TAO ORE Ez Or OE profile map HARAN ZOK SK O x Mm MX Now set some parameters in Profile 2 evcc gt set maxv 150 evcc gt set maxc 12 evcc gt show config bms Loop charger tsm2500 profiles i it Ze 3 maxv E AQ ON Mean O ON maxc gt Za AJA 12 DA termc 0 2A 0 2A termt E EN Or DZ ORE profile map LIVE 20K SK O x KAX Now return to Profile 1 and set some parameters in Profile 1 evcc gt set profile 1 evcc gt set maxv 160 evcc gt set maxc 15 evcc gt set linec j1772 evcc gt show config bms loop charger tsm2500 profiles i JA Z 3 linec s ULZ maxv SLO OY LOO Oy maxc 5 ADA 12 0A termc gt 0 2A UZA termt i 720 20 LAG SOE profile map LE x 20K x JK X 0 x 26 Apr 2015 EVCC v2 3 Finally delete Profile 2 Apr 2015 evcc gt reset profile 2 evcc gt show config bms loop charger tsm2500 linec Be a maxv 160 UV maxc 154 0A termc 0 24 termt 20 O qua set map This command sets the profile map The EVCC measures resistance to ground at the PSelect input and divides the
48. rrent from the service connection and does not configure maxc This approach will perform a power calculation as a convenience for the user When the EVCC computes the maximum power available from the service it derates it by a nominal 90 charger efficiency and then computes an appropriate value for ChargeCurrent sl 2 EVCC v2 3 Apr 2015 ChargeCurrent linev linec 9 maxv Set linec to J1772 do not configure linev or maxc In this case the user specifies available line current to be J1772 In this case the EVCC measures the J1772 Pilot signal duty cycle in percent J1772DutyCycle and converts it to available charge current per J1772 this is given as 6A of charge current per 10 duty cycle Line voltage is not known in this case and so the EVCC uses the following rule If the duty cycle is gt 25 then the line voltage is assumed to be 220V and if the duty cycle is less than 25 then the available line voltage is 110V ChargeCurrent 220 J1772DutyCycle 6 9 maxv if J1772DutyCycle gt 25 110 J1772DutyCycle 6 9 maxv if J1772DutyCycle lt 25 These design assumptions are driven by what is currently available in the market today in North America EVSE equipment typically of two types one that connects at 220V rated at 30A with a 50 duty cycle The second type of equipment connects at 110V rated at 12A with a 20 duty cycle Set linec to J1772 set linev do not configure maxc
49. s a program that allows the user to easily access and program the EVCC via OS X 1 Go to http freeware the meiers org 2 Click download for mac Application Version Description CoolTerm is a simple serial port terminal application no terminal emulation that is geared towards hobbyists and professionals with a need to exchange data with hardware connected to serial ports such as servo controllers robotic kits GPS receivers microcontrollers etc CoolTerm Written in REALBasic NOTE Starting with v1 4 4 the official Mac build will only support Intel based Macs OS X 10 7 or newer is required For a universal binary supporting OS X 10 6 or older click here NOTE The LINUX version is not officially supported While almost everything is expected to work as expected virtually no 1 4 4 testing has been performed to confirm that all the features work properly I have no LINUX system that I can use for testing and debugging The LINUX build has been posted here as a courtesy to the users that asked for it Please use this build at your own risk Please use the forums to share your experiences with other users Linux Screenshot Books that mention CoolTerm t Info e Building Wireless Sensor Networks by Robert Faludi e Making Things Talk 2nd Edition by Tom Igoe e Arduino Cookbook by Michael Margolis 3 Extract the zip file open the CoolTermMac folder and drag the CoolTerm app into the applications folder 0960 7 Coo
50. s command changes the CAN IDs of a tsm2500 charger xxx ONLY ONE tsm2500 charger should be powered up at this time ii kik x Proceed Y N If you type y the EVCC then prints Programming the charger and then 5 10 seconds later it prints Programming the charger done The charger must now be power cycled evcc gt At that point the new charger will be programmed to tsm2500 42 and it will be configured in the evcc as charger2 Charging with Multiple Chargers When charging with multiple chargers maxc 1s divided by the number of chargers and given to each charger So here is an example of charger tracing when maxc is set to 12A Note that 6A goes to both TSM2500 and TSM2500 42 Note that trace charger reports the status of the charger and that voltage current watts and watt hours may be slightly different evcc gt trace charger charger tracing is now ON OOS LOr26e6 EsmZo00 423 VelZo U AS 506 N 150 Wh 0 10 OOS IO r202 CSMA V 126 3 A 5 9 W 745 Wh 0 09 JOIO 9v3 TmsZ2500 AZ V 120 6 A set WIZ Wh 0413 OUT LUG 2955 802500 V 126 6 A 5 8 W 34 Wh 0 19 OOS LUE 2926 temZ50U 422 ValzZi 2 B J97 NS732307 Wh 0 50 JOIO AI tem2o00 423 VelZieZy AS Jer Walo0 Nis Usal OOS temz2o00 423 Vall 2 AS Dad WSU NOS 0 53 JO rI Comodo 423 ValZiady AS 3497 W 73U0 NIS 0 54 00T10 3040 CsmZo00 42r V l27 4y A 549 N 730 Wh 0 56 OOFLOFSU TT ESmzo00 422 VSI27s27 B Seo N 150 WO 0 57 OFTES CsmZo00
51. t will remain powered ON until power is removed from HotInRun To start charging again it is necessary to cycle power to the EVCC EVCC v2 3 Apr 2015 Cell Loop and Buzzer The EVCC is intended to be installed with a Battery Management System that monitors per cell over voltage conditions when charging and per cell undervoltage when driving The EVCC Cell Loop surveillance circuit measures the resistance of the circuit between CellLoop1 D1 and CellLoop2 D2 The circuit applies 5v to Cell Loop and limits the current to about 2ma It is expected that the Cell Loop be implemented using a solid state relays or optoisolators Connecting the cell loop to the contacts of a mechanical relay is not recommeneded as the cell loop may not provide enough wetting current for the relay contacts The Buzzer D3 output provides up to 200ma at 12V that can be used to sound a buzzer when there is a pack fault error The operation of the buzzer depends on how cell surveillance is configured in the EVCC By default cell surveillance is performed by the cell loop However cell surveillance can also be disabled performed by a CAN BMS or performed by both the cell loop and the CAN BMS See the command set bms below WARNING It is strongly recommended that per cell monitoring be performed on the pack so that charging can be stopped if any cell exceeds a high voltage or low voltage cutoff Lithium batteries can be dangerous if overcharged or undercharged
52. the keyswitch When driving the EVCC can be used as a simple BMS Master an can sound a buzzer when a cell undervoltage error is detected EVCC features work largely independently and it is not necessary to wire up or use all features Installation may be customized per customer requirements The EVCC is housed in a 4 55 x 5 13 x 1 67 automotive grade water resistant enclosure Connections are made with a single 18 pin connector The EVCC is shipped with a pre wired harness and with a USB to serial port cable _4 EVCC v2 3 Apr 2015 Installation and Theory of Operation Mechanical The enclosure outline is shown below The EVCC can be mounted in any convenient location however would ideally be located physically close to both the charger and the J1772 charge port 4 000 015 101 60 0 38 Figure 2 EVCC Enclosure The figure below shows the 18 pin connector and wiring harness Note the LED to the right of the connector and the serial port jack to the left of the connector Figure 3 EVCC Connector and Front Panel The figure below shows the EVCC pinout e gs Ei ra im ono Pi Coco No cam fc Peet Foxy Figure 4 EVCC Pinout Power B and GND Al A3 are Power Inputs and should be connected to the EV 12V accessory battery HotInRun A2 is connected to the Ignition swich Supplying 12V to HotInRun will turn the EVCC on EVCC v2 3 Apr 2015 ChargeStart B1 is used t
53. ur charge profiles in tabular form The charge profile selected for editing is indicated with a Also the profile map is shown Example output with multiple charge profiles is shown below evcc gt show c bms loop charger tsm2500 profiles 1 PA 3 4 linev i 220 09 linec 30 0A J1772 maxv LS a UM Lo S R UM maxc i 190A 2 0A maxbc i Th eo termc 0 2A ez termt Ed No owJhr fin maxv 160 0V fin maxc 2 OA fin termi 4 0hr FLE maxv amp 152504 flt maxc 0 5A ELE ternit O ars profile map ini i X 20K X 5K i X O i x show history The show history command displays data about the last sixteen charge cycles See also reset history below In the first example the system has no charge history yet evcc gt show history no charge history The next example shows charge history with different termination reasons The termination reason contains the reason that the charge cycle stopped In this example in the most recent charge attempt the user disconnected the J1772 plug one minute after charging started EVSE disc 1 mins The previous attempt 1 shows a normal charge completion with a charge time of 214 minutes and includes the number of watt hours delivered Note that the voltage and current measurements are provided by the charger in the CAN message to the EVCC The EVCC does not measure pack voltage or current term charge watt maximum maximum ending num reason
54. will print help for the set command evcc gt set SEE lt gt BMS CHARGER CHARGERZ CHARGERS CHARGER4 PROfile MAP EXTINDCHARGE CANTERMDIS LINEV LINEC MAXV MAXC MAXBC TERMC TERMT FIN MAXV FIN MAXC FIN TERMT FLT MAXV FLT MAXC FLT TERMT lt gt set help bms configuration set bms NONE LOOP CAN LOOP CAN charger configuration lt chargern gt CHARGER CHARGER2 CHARGER3 CHARGER4 lt model gt TSM2500 TSM2500 41 TSM2500 42 TSM2500 43 ELCON ELCON E7 ELCON ES ELCON E9 set lt chargern gt lt model gt defines lt chargern gt set lt chargern gt NONE deletes lt chargern gt set lt chargern gt lt type gt PROGRAM programs TSM2500 CAN IDs Service parameters set linev lt v gt available line voltage set linec lt a gt J1772 available line current BULK charge parameters set maxv lt v gt maximum charge voltage 24 EVCC v2 3 Apr 2015 set maxc lt a gt maximum charge current set maxbc lt a gt maximum balancing current Set terme lt a gt charge termination current set termt lt m gt charge termination timeout SLA charge parameters set fin maxv lt v gt finishing charge voltage Set CIA MARE lt a gt Tinishing charge Current Sel fin cerme lt m gt finishing charge termination timeout set ilt maxv lt v gt float charge voltage set FIT maxo lt a gt float charge current set flt termt lt m gt float
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