EVCC Manual version2
Contents
1. co om GND J172 cutback Proximity Figure 5 Power Connections od eas 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 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 EV chassis ground power pilot proximity ground Figure 6 Face of J1772 Socket 2G EVCC v2 1 Firmware Feb 2015 The J1772 Proximity signal allows the EV and the EVSE to determine whether the J1772 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 The J1772 Pilot signal is used by the EV to indicate to the EVSE that it 1s ready for charging Using this signal the the EVCC can enable and disable the relay in the EVSE that supplies line power to the charger The figure below shows the J1772 connections EVSE EVSE Charge WOq euas2. 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 39
3. normal 214 mins 3249wWh 152 9V 7 9A 0 5A 2 EVSE disc 1 mins Owh 144 8V O OA D OA 3 comm err O mins OWh 0 0V 0 0A 0 0A evcc gt The full set of term reason codes 1s e EVSE disc J1772 charge plug became unlocked while charging 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 22 EVCC v2 1 Firmware Feb 2015 The format of the charge history is modified to show the contribution of each charger when multiple chargers are configured evcc gt show history term charge watt maximum maximum ending num reason time charger hours voltage current current last EVSE disc 2 mins ch4100 6Wh 127 8V 2 2A 0 0A ch4100 42 6Wh 127 5V 2 0A 0 0A TOTAL 12Wh 127 8V 4 2A 0 0A 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 will print additional help for the set command evcc gt se
4. DE HotlnRun 12V Ch Y Cell Loop2 CANL CANH ICI MEMES Figure 7 J1772 Connections 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 to indicate that the plug is locked When J1772 is not being used the EVCC J1772 Proximity may be connected to GND through an external 150 ohm resistor directly The EVCC is also tolerant of a direct e g 0 ohm connection to ground and so the 150 ohm resistor is optional 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
5. charge watts available assumes 90 conversion efficiency 3 cutback maxc charge watts maxv cutback charging current The diagram below shows the charge cutback connections af eB of Ec e es Se Se fee WOq eas 2 HotinRun 12 Ch E Cell Loop2 CAN CANH GND GND pute Proximity Figure 10 Charge Cutback Connections EVCC v2 1 Firmware Feb 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 assumed is that each node on the CAN network is grounded to chassis ground A CAN network is a daisy chain multistation network that should be terminated on both ends of the string by 120ohm termination resistors See below for a simple network diagram charger CANL Figure 11 CAN Network Diagram CAN wiring should be kept short and the conductors should be twisted Wiring should be placed away from EMI ElectroMagnetic Interference such as the motor and controller and parallel runs next to the 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 case hand twisted wiring should be fine In practice there will be some amout of stub between the CAN network and the device These stubs should be kept as shor
6. 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 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 O02 0 22 7 25 evec 168604024 fc es 00 Ge 0c Tr Tt EE 00 01 27 4 ch4100 41 18eb2441 01 fd 00 00 80 Oc 38 ff a5 EVCC v2 1 Firmware Feb 2015 EES ELE 18eb2440 00 fc 4b 04 80 Oc 4a ff Os 0L 2 700 evcc 18e54024 fe c8 00 be Da fE ZE EL 00 01227 9 ch4100 41 18eb2441 01 Ta 00 00 80 0c 30 Tf EK LE E EIER 18eb2440 00 fc 4b 04 80 Oc 4a ff LEA S evcc 18e54024 te c8 DO 6c He ZE ff ff 00 01 28 4 ch4100 41 18eb2441 01 fd 00 00 80 Oc 38 ff 00 01 28 45 ch4100 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 DRI
7. 6 Ground Charge start The EVCC should power up and go into Charge state 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 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 3 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 1 Firmware Command Line Interface Startup Banner When the EVCC is powered up it will print the following Feb 2015 KKEKKKKKKKRKKKKKKKKKKKKKRKKKKRKKKKKKKKKKKKKRKKKKRKKKKKKKKKEKKEK EV Charger Controller v2 1 0 Thunderstruck Motors Dilithium Design kk kk kk Ek E kk kk kk Ek E kk Ak Ek E kk RARA evcc gt help The help command prints out command help evcc gt help SHow SEU REset TRace lt gt set help History history reset charge history 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 CUTback des measure help loop measure Cell Loop A D proximity measur
8. 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 1n the equipment and do not claim to provide for every possible contingency met in connection with installation operation or maintenance It is strongly recommended that the user check with their battery supplier to determine appropriate charging parameters 343 EVCC v2 1 Firmware Feb 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 is simpler to install and use CoolTerm is 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 g
9. a G 4 p 2 ENEE SS SA Y e cell loop P CR e a sas w Y PACK EV Charger Controller Figure 13 Multiple Chargers System Diagram Note that there is a single J1772 interface for line power which feeds all chargers The chargers are in 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 is 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 requires 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
10. bms gt loop charger ch4100 charger2 ch4100 42 maxv AS RA maxc 12 0A termc 0 5A termt 4320 min evcc gt A charger can be deleted by setting the model to none evcc gt set charger2 none Programming a CH4100 Charger This section describes how to set the CAN addresses of a programmable CH4100 charger If this procedure is performed on a charger that does not support it it will have no effect 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 ch4100 42 Ifthe charger is already programmed as model ch4100 42 then it would only be necessary to use the command set charger2 ch4100 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 29 EVCC v2 1 Firmware Feb 2015 evcc gt set charger2 ch4100 42 program The EVCC will then print kx kxx SE CH4100 PROGRAMMING SE WARNING This command changes the CAN IDs of a CH4100 charger ONLY ONE CH4100 charger should be powered up at this time SEH KEEN Proceed Y N If you type y the evcc then prints Programming the charger and then 5 10 seconds later it prints Programming the charge
11. 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 28 EVCC v2 1 Firmware Feb 2015 charger and so that charger must be at the end of the CAN string Keep wiring stubs as short as possible Shielded cable may be required Each charger must have a unique CAN address In EVCC terminology the charger model determines both the charger manufacturer as well as the charger CAN address The following sections describe what charger models are supported See Charger Support for the charger models supported 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 ELCON and one CH4100 at the same time The following example defines a single charger and sets its model to ch4100 evcc gt set charger ch4100 evcc gt show config bms Loop charger ch4100 maxv Loge UV maxc 12 0A termc 0 5A termt 4320 main evcc gt This example defines a second charger and sets its model to ch4100 42 evcc gt set charger2 ch4100 42 evcc gt show config
12. 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 bleeding 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 conditions 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 unsign
13. CC STATUS IND does not arrive then this is treated as a loop open 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 j Charge Current Si j 10 13 C 2 45V to 2 79V 25 C 77 F 2 35V to 2 45V 25 C 77 F 1 3 C 20 90 100 State 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 thou
14. HotInRun The EVCC will power up and begin charging When the EVCC completes charging it will stop sending CAN messages to the charger and turn off 12V_ Ch but will remain powered ON until power is removed from HotInRun To start charging again it is necessary to cycle power to the EVCC 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 Cell Loop 1 and Cell Loop 2 if the circuit is open then the cell loop is considered failed The circuit applies 5v to Cell Loop1 and limits the current to about 2ma It is expected that the Cell Loop be provided by a solid state relay or optoisolator Connecting E 3 EVCC v2 1 Firmware Feb 2015 the cell loop to the contacts of a mechanical relay 1s not recommeneded as the cell loop current may not be enough wetting current for the relay contacts 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 Use of the cell loop is the default operation However cell surveillance can be done either by the cell loop or by CAN messaging or both See the command set bms below The EVCC s
15. Thunderstruck Motors EV Charger Controller v2 0 v2 1 Firmware EV Charger Controller v2 0 F W Dilithium Design connec EVSE EVSE Disc1 Disc2 ell HotinRun Buzzer 12V_Ch Pilot L GND GND GND Proximity 2015 Dilithium Design EVCC v2 1 Firmware Feb 2015 Contents ACT VCS us e E E E A E EA T A A 3 e E EE T 5 Mecham ea UE 5 e 5 IE E I E E NAA EE S A A A T A oo RD T 6 CAMEO and BOZE anA EE AA EEA ON O TOANE NENTE 7 Piven Ee AS 8 EE 8 CANDU ee 10 Ss A PP o 13 EUR e 13 COD RE e 17 Si o o E RCE ODE SRA PA PRN O SRU 17 Bringup Checklist and Troubleshooting Hints 20 0 0 ccesssesseccccccceeceuseeeeeeccceeeesaaaaeseeeecceeeeeesuaeseeeeccceessaaaaaaeeeeeeeeess 19 Command e Eege 20 SA A AA OND SD TEN SR O TR 20 Eeer 20 Eege 20 REENEN 23 EEN 25 EE 26 Configuring the BE VCC with Multiple COSES ii aa 28 Egeter 28 CAN WM Fs e 28 BYOC EE E o ME 29 PO iat E EE rasa 29 EE witi EE 30 et AR Oye Oh We EE RE 31 EWERT 31 EE ODT e EE 31 E Fea 8a a Lead WEE a A eo peo UU ee E eee er 32 BU Ee 32 E A E 33 Foar E 33 EVCC v2 1 Firmware Feb 2015 EEN 33 Mac OSX Driver Insta e E 34 NV ARM ee ee GE 39 Document ON ee dE 39 2 EVCC v2 1 Firmware Feb 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 a
16. VE 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 J1772 WAITING FOR DISC term rsn EVSE UNLOCKED 00 07 17 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 1s 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 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 gt Geo OR proximity JlL772 Proximity A D gt 40V disconnected gt 2Zeov Connected else locked cutback Cutback A D lt 4 0V enabled evcc gt measure loop The measure loop comma
17. 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 the keyswitch When driving the EVCC can be used as a simple BMS Master an output is provided that can be used to sound a buzzer if 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 30pin connector The EVCC is shipped with a pre wired harness and with a USB to serial port cable _4 EVCC v2 1 Firmware Feb 2015 Installation Mechanical The enclosure outline is shown below It 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 30 pin connector and wiring harness Note the LED to the right of t
18. e J1772 Proximity A D cutback measure Cutback A D lt gt Version Config History lt gt Status version firmware version config Contigurcation history charge history lt gt BMS CHARGER CHARGER2 CHARGER3 CHARGER4 MAXV MAXC MAXBC TERMC TERMT FIN MAXV FIN MAXC FIN TERMT FLT MAXV FLT MAXC FLT TERMT LINEV_CB LINEC CB 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 will be displayed If show is entered without parameters current status 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 20 cell loop proximity buzzer CAN Errs charger uptime evcc gt show EVCC v2 1 Firmware OK EVSE not connected OFF TXERRCNT 0 RXERRCNT OU TX Abort 0 TX LARB 0 TX MSG ERR 0 not communicating O hour s O minute s 33 second s In the CHARGE mode the EV is charging State CHARGE cell loop OK proximity EVSE Connected and locked buzzer OFF CAN Errs TXERRCNT 0 RXERRCNT 0 TX Abort 0 TX LARB 0 TX MSG ERR 0 voltage LAP IV current 5 9A charger 306 msgs s
19. eared 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 P build at your own risk Please use the forums to share your experiences with other users Linux Screenshot Books that mention CoolTerm sg 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 000 7 CoolTermMac lt E Dio Sy BY Q o Favorites E Macintosh HD amo L Ch iCloud Drive TXT TXT AirDrop AppleScri E Desktop M Documents O Downloads H Movies J Music DEn Pictures rme CoolTerm app ReadMe txt CoolTerm Capture 2014 10 00 15 t
20. ed char BMS gt EVCC message Identifier ny define BMS EVCC STATUS IND 0x01dd0001 define BMS EVCC CELL HVC FLAG 0x0 setafac ll 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 Set il a cell is lt LVC 7 BMS gt EVCC message body Se typedet struct tBMS EVCC statustaad uint8 bBMSStatusFlags see bit definitions above uint8 bReserved reserved set to 0 e 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 In v2 1 firmware 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 status 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 sg EVCC v2 1 Firmware Feb 2015 the EVCC will drop back into balance cutback If there is a message timeout and BMS EV
21. ent 320 msgs received uptime 0 hour s 3 minute s 30 second s Here is an example of CHARGE mode with Cutback is enabled evcc gt show state CHARGE cell loop OK proximity EVSE Connected and locked cutback enabled buzzer OFF voltage 146 5V current L ee charger 349 msgs sent 364 msgs received uptime O hour s 4 minute s 51 second s show version The version command displays firmware version number and build date evcc gt show version version v2 0 Sep 23 2014 12 04 16 evcc gt show config The show config command displays configuration parameters evcc gt show config bms loop charger CH4100 maxv 8 40 0V maxc 2 0A termc 0 2A termt 4320 min evcc gt These are e bms the bms type cell loop can or both e charger the configured charger model Me Feb 2015 EVCC v2 1 Firmware Feb 2015 e charger2 4 present if configured model types of chargers2 4 e maxv maximum charging voltage in Volts This is provided to the charger e maxc maximum charging current in Amps This is provided to the charger maxbc present if configured maximum balance cutback current e terme terminating charging current in Amps See text e termt maximum charging time in minutes See text e fin maxv present 1f configured finishing charge voltage for SLA charging e fin maxc present if configured finishing charge current for SLA charging e fin termt pres
22. ent if configured finishing charge current for SLA charging fln maxv present 1f configured float charge voltage for SLA charging fin maxo present if configured float charge current for SLA charging e flin termt present if configured float charge current for SLA charging e linev cb present if configured line voltage if cutback is enabled linec cb present if configured line current if cutback is enabled 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 evcc gt show history term charge watt maximum maximum ending num reason time hours voltage current current last EVSE disc 1 mins 7Wh 148 9V 7 9A 7 9A 1
23. eries d E Biometric F Printers and Regionaland Hardy Sai Bluetooth Faxes Language d Computer E a et Or Continue Open Off A 44 44 4444 EE DEE 2 EEN By Motors Ele Step 3 Install a terminal console program e g a telnet client on the host computer 13 EVCC v2 1 Firmware Feb 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 Features ES Window XONMOFF Do not hit Open just yet Go back to Session by clicking the word Session in the Category window 14 EVCC v2 1 Firmware Y PuTTY Configuration Logging El Terminal Appearance i Behaviour i Translation Selection D Jo o COMI5 5 a Window Lf Pen Telnet Dep SSH o Colours Deiauii Settings El Connection Feb 2015 Set the Connection type to Serial Give the new session a name in this case EVCC in the Saved Se
24. ght 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 C29 The bulk charge phase completes when the charging current drops to 1 3 of Cp 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 30 EVCC v2 1 Firmware Feb 2015 Finishing Charge For Lead Acid batteries the second phase of charging is the finishing charge 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 is considered an abnorma
25. harger plug is present The J1772 Pilot signal is used to start and stop charging by enabling and disabling the contactor in the EVSE Driveaway protection is supported so that the EV cannot be driven if the charge cable is still plugged in EVCC v2 1 Firmware Feb 2015 The EVCC supports CH4100 and ELCON CAN enabled chargers Charge voltage charge current as well as overall charge time 1s controlled completely by the EVCC over the CAN 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 unlocked 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 For Lithium batteries a charge cycle ends when the charging current drops below the minimum configured charge current Determining cell overvoltage errors and cell undervoltage error detection is the function of the EV Battery Management System BMS The EVCC can be configured to interface with the 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 1s provided for the last sixteen
26. he connector Depending on model the serial port jack may be on the front panel to the left of the connector or as part of an inline connector SEI AA O Figure 3 EVCC Connector and Front Panel The figure below shows the EVCC pinout EVSE EVSE E CANL CANH od Eug DE HotinRun 12 Ch a Cell Loop2 GND GND eno 172 cutback 12V Sw GND Proximity Figure 4 EVCC Pinout Power B and GND A3 are Power Inputs and should be connected to the EV 12V accessory battery _5 EVCC v2 1 Firmware Feb 2015 HotInRun is connected to the Ignition swich Supplying 12V to HotIn will turn the EVCC on Charge Start is used to start charging By grounding this input e g by a momentary pushbutton switch the EVCC will power up and latch the power on The EVCC automatically turns itself off when charging is complete 12V_Ch and 12V_Sw are outputs that can be used to drive 12V indicators relays or instrumentation 12V_Sw is switched to B when the EVCC is powered up 12V_Ch is switched to B when the EVCC is Charging These outputs are protected by 350ma resettable fuses Note The design intent of Charge Start and 12V_Ch is to mount a momentary pushbutton and a 12V 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 The figure below shows the Power connections EVSE EVSE a JM aum oem um 5 fosco
27. l 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 Ca 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 not 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
28. logy a charger model refers to both the manufacturer and its unique CAN address CH4100 Charger Models The EVCC defines the following CH4100 charger models e CH4100 default e CH4100 41 e CH4100 42 e CH4100 43 The default value for CH4100 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 provides the serial interface for the charger 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 e ELCON default e ELCON E7 e ELCON E8 e ELCON E9 7 EVCC v2 1 Firmware Feb 2015 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 deter
29. mine what IDs are being used The chargers will transmit these messages spontaneously and it is not necessary to configure the charger in the EVCC to perform this test 18 EVCC v2 1 Firmware Feb 2015 Bringup Checklist and Troubleshooting Hints EV Installation 1 Connect B GND HotInRun 2 Connect J1772 Proximity J1772 Pilot J1772 GND 3 Connect Cutback 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 cutback a Verify readings with cutback enabled and disabled Verify Charge Start and J1772 1 Connect Cell Loop 2 Plug in J1772 Plug 3 Apply 12V to HotInRun The EVCC should start charging LED blinks once per second 12V_Ch should be enabled 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
30. n 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 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 CH4100 The following command sets a second charger evcc gt set charger2 CH4100 42 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 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 minutes evcc gt set termt 480 set linev_cb set linec_cb This
31. nd gives a real time measurement of the cell loop evcc gt measure loop KI EVCC v2 1 Firmware Feb 2015 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 cutback The measure cutback command gives a real time measurement of the cutback input evcc gt me cutback evcc gt Cutback A D 4 99V Cutback A D 4 99V Cutback A D 4 99V Cutback A D 4 99V Cutback A D 4 99V 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 Proximity A D 4 45V 27 EVCC v2 1 Firmware Feb 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 mm D emm SN SEN ES mmm oe 120 Q 120Q optional e 5 he e VO se H RAR fekt o o
32. olTerm Serial Port Serial Port Options a Port Y 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 36 EVCC v2 1 Firmware Feb 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 A ASCII View Options Cancel 9 Click Connect 0090 CoolTerm_0 Da K 3 fe O New Open Save AConnec isconnect Clear Data Options View Hex Help usbserial FTGDTR8M 9600 8 N 1 i TX y RATS 4 DTR 4 DCD Disconnected RX dy CTS y DSR y Al 10 Press the return key the EVCC command prompt should come up De ef EVCC v2 1 Firmware Feb 2015 000 CoolTerm_0 ISO E X Ml New Open Save nine Disconnect Clear Data Options View Hex Help evcc gt usbserial FTGDTR8M 9600 8 N 1 Tx ATS DTR DCD Connected 00 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 gene
33. ounds the buzzer if the a cell exceeds the high voltage cutoff depending on the configured bms options The Buzzer output is connected to B fused to 350ma The figure below shows the Cell Loop and Buzzer connections EVSE EVSE Charge WOq euas DE HotInRun DCH 12V Ch KE cell Loop2 CANL CANH GND enp 917 2 Cutback 12V Sw GND 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 the relay contacts EVSE Discl and EVSE Disc2 These contacts are fused to 350ma and are open if the J1772 cable is plugged in or if the EVCC is not powered Conversely the contacts are only closed and it is safe to drive if the EVCC 1s powered up and the cable is not plugged in How to disable the EV from driving is up to the EV designer These contacts could be wired into the control logic of the primary contactor Note The EVSE Disc1 2 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 350ma fused limit The figure below shows the connections used for Driveaway Protection Aa B c bD E F H K Charge EE dE e l ee 2 HotinRun 12 Ch da Cell Loop2 CAN CANH GND GND eno 1 72 Cutback 12V Sw GND Proximity Figure 9 Driveaway P
34. r done The charger must now be power cycled evcc gt At that point the new charger will be programmed to CH4100 42 and it will be configured in the evcc as charger2 Charging with Multiple Chargers When charging with multiple chargers maxc is 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 ch4100 and ch4100 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 0031032828 Cnal00 42 V 1260 0 A 329 W 7 5307 Wh 0 10 00 10 28 9 ch4100 V 126 3 A 5 9 W 745 Wh 0 09 WUT Jet EnAaLOUO 422 VelZ0 0 AS 2277 W 721 Wh Dado OUT Ee ChALOO V 126 6 A 5 8 W 34 Wh 0 19 00107290 CAAL0O 423 Ve lZIsZ AS 2 9 WHlo0 Whe Us 30 Kee CHhALOD 42 V LZIoZ A Tady NETO Wh 0 51 JOLO 29 9 Cmal00 42 e ee A Bade Weslo WAS Ek O0TLOTS0 0 caaloO 427 VHlZ 2 A tr W 1 90 Wh 0 34 Ke LE o0 Cmal00 423 e ek f dad NEE Whe 0 56 JULU 90 1 EH 42 Velo Plz A gt Dat W 1907 Wis 0 87 US LOTOUer cma l00 422 Veliz Dery WST307 Wh 0 59 OOS Le bb Cnal00 422 Vell A 2 9 W lo0 Wh 0 40 JOIO S020 CRHALVO 4243 VelZiw2 A 2 97 W 190 Wh 0 42 JOTO S024 Cnal00 422 V l2 asyr A Jay WU Wh DAS OO S102 30 5 Cn4100 422 Ne e AS 3 0 W 90 Wis 0 44 30 EVCC v2 1 Firmware Feb 2015 Integration
35. rate an ASCII 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 ASCII DEL character can usually be generated by MAC keyboards look for another delete key with an x or try pressing FN DEL 3 8 EVCC v2 1 Firmware Feb 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 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
36. re Feb 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 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
37. ressing These parameters are not software configurable however both the CH4100 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 allowable maximum values of charge voltage and charge current and the second message from Charger to EVCC that reports the actual Charging Voltage and Current in addition to 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 the charging will terminate EVCC BMS CAN messages communicate pack status See 11 EVCC v2 1 Firmware Feb 2015 Integration with CAN Enabled BMS below for the 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 facilitate debugging the EVCC reports CAN error counts in the show command In addition there are both high level tracing trace charger and a low level tracing trace can facilities to show CAN message traffic Os EVCC v2 1 Firmwa
38. rotection Connections WOq eas Charge Cutback Usually charging will be performed with the maximum current that the EVSE and Charger can support In some cases such as opportunity charging with a 110v outlet 1t may be necessary to limit the maximum charge current to avoid tripping a circuit breaker The Charge Cutback feature is designed for this case To use this feature it is first necessary 8 EVCC v2 1 Firmware Feb 2015 to configure line voltage and current values during cutback operation Use the commands set linev_cb and set linec cb Note Previous versions of EVCC firmware specified a charge cutback current maxc cb The maxc cb parameter has been removed in v2 1 firmware line voltage and linev cb and linec cb are to be used instead Once configured Cutback is used to determine the charging current If the Cutback signal is not grounded then the current is specified set maxc is used if the Cutback signal is grounded then the maximum current is reduced according to the power available from the line Example if the cutback will be used with a 110V 12A circuit then linev cb 110 linec cb 12 For reference the EVCC converts this into a maximum charging current by the following formula charging current when cutback linev cb linec_ cb 9 maxv This is derived as follows 1 line watts linev_cb linec cb power in watts available from the line 2 charge watts line watts 9
39. s 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 and replaces the head end board acting as a BMS master The EVCC can also interface with CAN enabled BMSs in that case the EVCC provides J1772 and Charger Control functions Charge Start 12V_Ch Cutback Ground J1772 Pilot USB to serial cable Driveaway protection canbus we power i ns e HotinRun 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 When charging a 12V output 1s provided which can light an indicator light or drive a relay The EVCC is configured using a simple serial interface The serial 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 c
40. s 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 16 EVCC v2 1 Firmware Feb 2015 LED Operation The LED has the following operating states e Solid ON Drive Mode e Blink once per second Charging e Fast Blink eight times a second Cell Loop Error Charger Support This section gives details on which charger models are supported by the EVCC CH4100 See CH4100 Series High Efficiency Intelligent Charger ThunderStruck User Manual Ver 1 0 2 http www thunderstruck ev com images ThunderStruckCH4100Manual1 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 There are two versions of CH4100 charger The frst version has an integrated termination resistor These chargers are shipped with the default CH4100 CAN addresses and cannot be reprogrammed The second version of CH4100 charger does not have an integrated termination resistor and the CAN addresses on these chargers can be reprogrammed The procedure to program the addresses is described below Programming a CH4100 Charger Note that address programming may have been done at Thunderstruck as part of the order Each charger requires a unique CAN address In EVCC termino
41. 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 Control Panel i Tew Favorites Tools Help ay Free Space Comments Deak EJ wi Search Folders X F Y Y Y Ki System Properties 2 x Address E Control Panel System Restore Automatic Updates se General Computer Name ardware Control Panel Accessibility Add Hardware D Switch to Category View Options Device Manager The Device Manage lists all the hardware devices installed E E E on your computer Uz the Device Manager to change the properties of any devide See Also Folder Options Fonts Device Manager Ba Windows Update CT e Device Manager Ego Disk drives E Display adapters 2 DVD CD ROM drives 2 IDE ATA ATAPI controllers IEEE 1394 Bus host controllers 5 gt Keyboards 15 Mice and other pointing devices Modems Monitors Sai Network adapters Ce E PCMCIS adapte F Ports COM amp LPT EI Communications Port COM1 AB X IDE ThunderStruck 7 EI USB Serial Port COM15 O Help and Support A A e d ei ES File Action view Help F Mouse Network N DE ER e Cp a Connections R k w A Batt
42. sets the maximum line voltage and line current available when the Cutback input is enabled evcc gt set linev_cb 110 evcc gt set linec cb 12 24 EVCC v2 1 Firmware Feb 2015 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 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 history The reset history command resets the charge history evcc gt reset history charge history has been reset evcc gt 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 independently 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
43. ssions 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 E Terminal E Window Appearance Behaviour Translation Selection Colours E Connection A screen like the following should appear 15 EVCC v2 1 Firmware Feb 2015 comis 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 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 command
44. t SEE lt gt BMS CHARGER CHARGER2 CHARGER3 CHARGER4 MAXV MAXC MAXBC TERMC TERMT FIN MAXV FIN MAXC FIN TERMT FLT MAXV FLT MAXC FLT TERMT LINEV_CB LINEC CB lt gt bms configuration set bms NONE LOOP CAN LOOP CAN charger configuration set help lt chargern gt CHARGER CHARGER2 CHARGERS CHARGER4 lt model gt CH4100 CH4100 41 CH4100 42 CH4100 43 ELCON ELCON E7 ELCON E8 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 CH4100 CAN IDs BULK charge parameters set maxv lt v gt maximum charge voltage set maxc lt a gt maximum charge current set maxbc lt a gt maximum balancing current set termo lt a gt charge termination current set termt lt m gt SLA charge parameters Seu fin Mazy lt y gt set fin maxo lt a gt charge termination timeout finishing charge voltage finishing charge current set tin cerme lt m gt Tanashing Charge terminacion timeour set ilt maxy lt v gt float charge voltage set flt maxo lt a gt float charge current set CUC Cerne lt m gt float charge termination timeout 0 no timeout Service cutback set lanev cb lt v gt set linec ch lt a gt cutback line cutback line voltage current 23 EVCC v2 1 Firmware Feb 2015 set bms This sets the BMS type The EVCC ca
45. t as possible to minimize reflections and bus interference For longer runs more nodes or cases where EMI may be an issue shielded cable is desirable If a 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 EVSE EVSE Charge DE HotinRun 12 Ch SE Cell Loop2 GND GND eno 11 72 Cutback Proximity Figure 12 CAN Connections WOd EUag CAN Connections Note that the EVCC supports a single CAN interface but brings out two sets of CANH CANL pins on its connector One pair G1 H1 is wired to a CAN termination resistor in the harness The CH4100 charger may include an internal 10 EVCC v2 1 Firmware Feb 2015 termination resistor If so then connecting a two node system between EVCC and CH4100 charger it is necessary to simply connect CANH CANL between the devices If other chargers are used or if more nodes are added to the CAN network then the CAN network must be wired in a serial point to point fashion between nodes with 120ohm resistors at the ends of the string Terminal nodes must have a 120ohm termination resistor If it is not in the charger then it should be placed across CANH and CANL as close as practical to the Signal Connector If the EVCC is not a terminal node in the network the resistor may be removed and the CAN string may be extended CAN Protocol The EVCC supports a CAN data rate of 250Kbs and 29 bit CAN add
46. xt 94 EVCC v2 1 Firmware Feb 2015 4 Open the applications folder and double click CoolTerm app 0090 Es Applications lt D mm gt Q Favorites E Macintosh HD A A A O Cloud Drive AirDrop App Store app Automator app Calculator app Calendar app Applications E Desktop Ki Documents lt amp Downloads Chess app Contacts app CoolTerm app Dashboard app Movies fi Music Pictures ad Bn be Google Drive Dictionary app DVD Player app FaceTime app Font Book app 5 Click Options eee ebe e W New Open Save Connect Disconnect Clear Data Bluetooth Incoming Port 9600 8 N 1 Ww TX Ww RTS W DTR DCD Disconnected RX Y CTS Y DSR amp Al 6 Ensure the baudrate is set to 9600 which should already be set by default 35 EVCC v2 1 Firmware Feb 2015 Serial Port Serial Port Options Leien Port Bluetooth Incoming Es gt Receive Transmit Miscellaneous Data Bits a A Parity none Stop Bits 1 Flow Control CTS DTR XON Initial Line States when Port opens O DTR On DTR Off ORTS On RTS Off Re Scan Serial Ports 7 Click the drop down menu and select usbserial lt sn gt where lt sn 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 Co
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