Chargepoint CT2003 transformation

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coulomb
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Re: Chargepoint CT2003 transformation

Post by coulomb »

Partial schematic trace of the mains (pilot) unit:

CT2000 AC unit.png
CT2000 AC unit.png (33.86 KiB) Viewed 175 times
CT2000 AC pilot.png
CT2000 AC pilot.png (25.37 KiB) Viewed 225 times
CT2000 AC pow&en.png
CT2000 AC pow&en.png (16.84 KiB) Viewed 225 times
MG ZS EV 2021 April 2021.
Nissan Leaf 2012 with new battery May 2019.
5650 W solar, 2xPIP-4048MS inverters, 16 kWh battery.
1.4 kW solar with 1.2 kW Latronics inverter and FIT.
Patching PIP-4048/5048 inverter-chargers.
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coulomb
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Posts: 5419
Joined: Thu, 22 Jan 2009, 20:32
Real Name: Mike Van Emmerik
Location: Brisbane
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Re: Chargepoint CT2003 transformation

Post by coulomb »

I'm paranoid about the evils of switching the EVSE relay under load, when it's pretty much guaranteed to be connecting to a power factor corrected front end, which always has a large inductor in series with the AC-in after a bridge rectifier. So I go to some trouble when pausing and switching off the charge to ramp the power down to 6 A (the lowest setting), then disconnect the pilot signal from the vehicle, then send the commands to stop the charge and open the relay. So disconnect the pilot signal, and connect it instead to +12 V from the pilot generating circuit, I used a simple Jaycar relay board:

Relay board sm.jpg
Relay board sm.jpg (262.97 KiB) Viewed 95 times
There are test points all over the AC board, and TP5 (circled in red) has +12 V.

It seems to do the job, and doesn't freak out my Leaf. I have not tested it on other EVs as yet. I may have to add a GUI control to disable that relay for some vehicles.
MG ZS EV 2021 April 2021.
Nissan Leaf 2012 with new battery May 2019.
5650 W solar, 2xPIP-4048MS inverters, 16 kWh battery.
1.4 kW solar with 1.2 kW Latronics inverter and FIT.
Patching PIP-4048/5048 inverter-chargers.
User avatar
coulomb
Site Admin
Posts: 5419
Joined: Thu, 22 Jan 2009, 20:32
Real Name: Mike Van Emmerik
Location: Brisbane
Contact:

Re: Chargepoint CT2003 transformation

Post by coulomb »

Here is an early version of the wiring harness to connect everything together. Missing is another cable for the two buttons, one of which has an LED behind it. It's surprising how many wires you need. The DC power connector shown wasn't reliable; it's since been replaced with the connector from the RF modem.

Early harness sm.jpg
Early harness sm.jpg (286.37 KiB) Viewed 95 times
This is how the top half wires together:

Top parts ready to assemble sm.jpg
Top parts ready to assemble sm.jpg (370.01 KiB) Viewed 95 times
The shiny metal in the hat that looks like brushed aluminium is in fact brushed stainless steel. It was a chore to cut to make clearance for the backbone connector.

All the above slide down on top of the AC unit:

Bottom part installed sm.jpg
Bottom part installed sm.jpg (192.72 KiB) Viewed 95 times
Finally, everything is inside the case, and it all seems to work. Now it's "just finishing the firmware" 😧

It's still using the temporary 1.5 mm² cable and 15 A plug. The orange 1.5 mm² cable looks incongruously thin compared to the other cables, especially the 30 A industrial strength cable to the J1772 connector. I'll order a type 2 connector soon.
MG ZS EV 2021 April 2021.
Nissan Leaf 2012 with new battery May 2019.
5650 W solar, 2xPIP-4048MS inverters, 16 kWh battery.
1.4 kW solar with 1.2 kW Latronics inverter and FIT.
Patching PIP-4048/5048 inverter-chargers.
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