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Step 8: Load EVSE firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Step 9: Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Step 10: High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Step 11: Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
http://www.instructables.com/id/Arduino-EV-J1772-Charging-Station/
Image Notes 1. A1 2. R5 - 56k Ohm 5V to A1 3. R6 100k Ohm from A1 to GND 4. R7 200K from A1 to pilot connection 5. R1 1k 1% resistor from opamp pin 1 (pilot output to pilot connection 6. Pilot Output
http://www.instructables.com/id/Arduino-EV-J1772-Charging-Station/
Image Notes 1. D5 - LED red 2. D8 - LED Blue 3. D13 - LED Green 4. RGB CC LED
http://www.instructables.com/id/Arduino-EV-J1772-Charging-Station/
http://www.instructables.com/id/Arduino-EV-J1772-Charging-Station/
Image Notes 1. Input 5V and GND 2. Output 12V, GND, and -12V
Image Notes 1. A1 2. R5 - 56k Ohm 5V to A1 3. R6 100k Ohm from A1 to GND 4. R7 200K from A1 to pilot connection 5. R1 1k 1% resistor from opamp pin 1 (pilot output to pilot connection
http://www.instructables.com/id/Arduino-EV-J1772-Charging-Station/
6. Pilot Output
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Image Notes 1. A1 2. R5 - 56k Ohm 5V to A1 3. R6 100k Ohm from A1 to GND 4. R7 200K from A1 to pilot connection 5. R1 1k 1% resistor from opamp pin 1 (pilot output to pilot connection 6. Pilot Output
Step 7: GFCI
Ground Fault Inturupt (GFCI) is an important part of a charging station. GFCI works by measuring the differance of current out verses current in. If there is a differance the circuit trips. Standard GFCI trips at 5mA, however EVs need a less sensitive trip point. Most comercial EVSEs use 20mA. This Circuit work by using a Ground Fault Current Transformer (CT) from CRMagnetics (CR8420-1000-G). THe CT creates a small voltage when there is a fault. The small voltage from the CT is first amplified in the first stage then compared to a referance voltage in the second. If the amplified CT voltage is higher than the referance the Opamp goes high and causes the Arduino to register an inurupt on Arduino pin D2. 1. On another protoshield solder a 8pin socket. 2. Solder power wires, pin 4 to 5v and pin 8 to Ground 3. Solder Diodes 1N4148 to the Op-amp outputs pins 3 and 5. Opamp Output A 4. Solder header pins for CT coil. 5. Solder zener diodes to the header. 6. Solder 330 ohm resistor R17 to the header. (the value of this resistor can be changed to change the GFCI trip point) 7. Solder R16 from the CT coil header to Opamp pin2 8. R17, and a .1uf Capacitor from Opamp pin 2 to the diode on pin 1. Opamp Output B 9. Solder R15 (20k) to Gnd and R14 (100k) to 5V, connect resistors together then to Opamp pin 6. 10. Connect Opamp Output pin 7 diode to 10K resistor and the to Arduino Digital 2 (D2), connect other end of resistor to Gnd.
http://www.instructables.com/id/Arduino-EV-J1772-Charging-Station/
http://www.instructables.com/id/Arduino-EV-J1772-Charging-Station/
http://www.instructables.com/id/Arduino-EV-J1772-Charging-Station/
http://www.instructables.com/id/Arduino-EV-J1772-Charging-Station/
http://www.instructables.com/id/Arduino-EV-J1772-Charging-Station/
Step 9: Testing
The J1772 Pilot is a 1khz +12V to -12V square wave, the voltage defines the state and the duty cycle defines the current available to the EV. The EVSE sets the duty cycle and the EV adds resistance from the pilot the Ground to vary the voltage. The EVSE reads the voltage and changes state accordingly. State Pilot Voltage EV Resistance Description State A 12 N/A Not Connected State B 9 2.74k Connected State C 6 882 Charging State D 3 246 Ventilation Required State E 0 N/A No power State F -12 N/A EVSE Error State A - To test State A, power up the EVSE. The EVSE should go to the ready state. LED should light Green. State B - To test State B, with the EVSE powered connect the EV Simulator (or diode and resistor) with a resistance of 2.74k Ohms. The EVSE should go to the EV Connected - EVSE ready state. LED should light Yellow. State C - To test State C, with the EVSE powered connect the EV Simulator (or diode and resistor) with a resistance of 882 Ohms. The EVSE should go to the EV Connected - EVSE ready state. LED should light Blue. State D - To test State D, with the EVSE powered connect the EV Simulator (or diode and resistor) with a resistance of 246 Ohms. The EVSE should go to the Error Vent required. LED should light Red. State E - To test State F, the EVSE should be disconnected from power. The EVSE should turn off, the LED should go out. State F -To test State F, with the EVSE powered connect the EV Simulator (just a resistor) with a resistance of 2.74k Ohms. The EVSE should go to the Error Diode Check Failed. LED should light Red. Frequency -The Pilot should have a frequancy of 1kHz(1000Hz). The acceptible J1772 tolerance is from 980-1020Hz. Test Frequency by attaching the EV simulator in State C "Charging Mode) (or diode and 882 Ohm resistor). Attach a multimeter or occiloscope from pilot to EVSE Ground. Pilot Duty Cycle - The Pilot Duty Cycle is dependant on the Max current setting of the EVSE. Test Duty Cycle by attaching the EV simulator in State C (Charging Mode). Attach an occiloscope from pilot to EVSE Ground. Duty cycle should match the chart below. Up to 51A Amps = Duty cycle x 0.6 Duty cycle = Amps / 0.6 51 - 80A Amps = (Duty Cycle - 64) 2.5 Duty Cycle Max Current < 3% Error 3% - 7% Digitial Com Required 10% 6A 20% 12A 30% 18A 40% 24A 50% 30A 60% 36A 70% 42A 80% 48A 86% 55A 88% 60A 90% 65A 92% 70A 94% 75A 96% 80A
http://www.instructables.com/id/Arduino-EV-J1772-Charging-Station/
Image Notes 1. Red - Error Vent required - State D 2. EV Simulator set to 246 Ohm
http://www.instructables.com/id/Arduino-EV-J1772-Charging-Station/
Image Notes 1. Hot 2. Hot to power supply 3. Neutral 4. Neutral to power supply 5. Ground
http://www.instructables.com/id/Arduino-EV-J1772-Charging-Station/
Image Notes 1. Hot from J1772 2. Hot from J1772 3. Neutral/Hot2 from J1772 4. Ground from J1772 5. J1772 Pilot
http://www.instructables.com/id/Arduino-EV-J1772-Charging-Station/
http://www.instructables.com/id/Arduino-EV-J1772-Charging-Station/
Image Notes
Image Notes
http://www.instructables.com/id/Arduino-EV-J1772-Charging-Station/
Image Notes 1. High Voltage parts 2. I need another shaller box for the Arduino and shields.
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