State of the mod request: CCS DC fast charging

14874 Views 60 Replies 14 Participants Last post by remy_martian, 3 mo ago

joekitch

Discussion Starter · May 31, 2020

some clarifications about what i mean:

onboard charge controllers or BMS' or both, not at-home charging boxes
CCS plug, not chademo. Chademo in my area especially is falling down very quickly and even then very few of them are even fast chargers
by "fast charger", i mean the standard 0-80% in 30 minutes speed
in my particular application, i'll be using only a 32kw total capacity battery, so having a way to fast charge so i don't need to worry as much about range is very high priority for my build

so, what's the current state of this? Last i heard, orion was looking into putting this into their BMS'
https://www.diyelectriccar.com/forums/showpost.php?p=1051737&postcount=4
but i can't find any evidence of aftermarket or open source approaches, let alone how successful they've been

Reactions: 1

21 - 40 of 61 Posts

Ladogaboy

· #21 · Jul 21, 2020

mpopov23 said:
Well there are a few key components:
1. GreenPHY PLC, cheapest one I found is this: PEV (Electro Vehicle) side PLC / Home Plug Green Phy communication Module for ISO/IEC15118 / DIN 70121 / SAE J2847/2 51 EUR
2. Singleboard computer capable of running ISO15118 stack, perhaps Beaglebone Black since it includes two CAN interfaces https://hr.mouser.com/ProductDetail/BeagleBoard-by-Seeed-Studio/102110420?qs=vmHwEFxEFR8FZOWBwz8ZDA== 40 EUR
3. Additional PCB with SAEJ1772 signaling and sampling, power suppply, etc electronics approx 50 EUR

so we are talking about 150 EUR just for the parts.

In addition you need:
1. At least two more high current DC contactors for connecting the CCS lines to battery pack (Tyco KiloVAC). around 200 EUR
2. High voltage, galvanically isolated voltage measuring input around 50 EUR
3. CCS socket, around 200-300 EUR.

As for the software, there is open source implementation in JAVA, RISE V2G – V2G Clarity, but it needs to be ported to the actual hardware, mostly by implementing calls to access J1772 CP and PP states and controling them. Also TCP/IP communication over PLC needs to be implemented.

I think 250-300 EUR just for the PLC module could be possible.

Yes, I think the best bet would be focusing solely on the PLC module. The CCS socket will be unique to the end user because Europe and North America use a different socket, and some people might already have the contactors (e.g., from a previous CHAdeMO conversion). Worst case, people buy the parts they need to complete the system separately, or we could set up a group buy for Tycos, sockets, cables, etc. if it makes sense.

I might pick up a spare Chevy Bolt EV Power Line Communication module for about $150 just to look at it and see how it works and is put together. It might only speak the DIN SPEC 70121 standard, though, which could be limiting.

Reactions: 1

sprombo

· #22 · Nov 10, 2020

joekitch said:
Orion's teasing a CCS add-on module to their BMS' which will come out late 2020 or early 2021 and that seems like a good relatively turn key solution

Do you have any source or information on this? I'm REALLY in the market for a BMS that can handle CCS and would love to have some info on it, any at all.

joekitch

Discussion Starter · #23 · Nov 10, 2020

sprombo said:
Do you have any source or information on this? I'm REALLY in the market for a BMS that can handle CCS and would love to have some info on it, any at all.

I have not emailed Orion asking about it, I encourage you to do so! Hopefully it didn't get delayed

sprombo

· #24 · Nov 10, 2020

Check it out! Zero EV (British EV conversion group) replied, and said a CCS charger will be hitting a market in like a month! Looks like it will be compatible with Orion BMS. And they'll have EU and US versions of CCS by middle of next year! Link to post.

Reactions: 1

Greenbeast

· #25 · Dec 15, 2020

sprombo said:
Check it out! Zero EV (British EV conversion group) replied, and said a CCS charger will be hitting a market in like a month! Looks like it will be compatible with Orion BMS. And they'll have EU and US versions of CCS by middle of next year! Link to post.

I just looked at their store and they have it up now, £3600

joekitch

Discussion Starter · #26 · 9 mo ago

I emailed orion recently asking for progress on this (on official orion ccs module that works with their bms2) and the individual on the other end linked me to the zero ev ccs module
which is....very concerning as it may indicate they've given up making one internally

Rustybkts

· #27 · 8 mo ago

joekitch said:
I emailed orion recently asking for progress on this (on official orion ccs module that works with their bms2) and the individual on the other end linked me to the zero ev ccs module
which is....very concerning as it may indicate they've given up making one internally

The Zero-EV module has been out of stock for over a year and still no date for coming back in due I guess to the global shortage of microchips.

Windydrew

· #28 · 4 mo ago

Any updates on ccs besides the i3 module?

joekitch

Discussion Starter · #29 · 4 mo ago

both aem and orion's solutions are "in progress" with a TBD release
aem just released their CCU, combined charging unit, onboard charger with dc/dc converter, im hoping with that done there's resources freed up for ccs
some random email from orion claims Q3-Q4 2023 release for orion but i would not get my hopes up

ga2500ev2017

· #30 · 4 mo ago

Anyone taken a look at the multiple Chademo/CCS DIY implementations over at OpenInverter.org?

Fast Charging - openinverter forum

The common method is taking a CCS control module from a modernish EV and using it to control the communications and monitor CCS conditions. Seems to be a better approach that starting from scratch with a bare "vaporware" module since these are from production EVs.

ga2500ev

remy_martian

· #31 · 4 mo ago

Last I looked, it was Europeans doing the work on EU-destined OEM hardware platforms.

Has that changed?

Windydrew

· #32 · 4 mo ago

Yes. Damien has made the BMW i3 CCS module work outside of an i3. Issue I have with it is it requires a specific contactor and charge port that I don't have available.

remy_martian

· #33 · 4 mo ago

What do you mean, "yes"?

No matter which Saint has hacked an EU-destined system, has someone in AMERICA shown it to work here on an American public charger? Nobody I knew of, last I looked.

Has that changed?

iirc, the Tesla M3 and i3 PLC modems are different here than in EU.

Windydrew

· #34 · 4 mo ago

I was replying to ga2500, yes. I've already purchased a dousida charge port so I'm not sure I'll be able to use the i3 LIM module but I do have most of the parts for the LIM in case that's my only option. Currently the Teslarado only has 1 Gen1 Volt pack so CCS isn't required. But in planning either a Model 3 pack, or some new future model once the time comes to go big.

remy_martian

· #35 · 4 mo ago

What makes CCS "required"?

A Volt pack can charge on CCS as easily as a Tesla one.

Windydrew

· #36 · 4 mo ago

15kWh will give me like 20 miles of range in my silverado. So I won't be fast charging. I'm putting in a 30kw diesel generator instead of more batteries to prove it can be done. So CCS would be pointless.

remy_martian

· #37 · 4 mo ago

To prove what can be done?

If you run the truck off that generator it, has to meet emissions tests/regs, which it won't pass. You could get screwed with a hefty emissions tampering citation. Yes, even as a "range extender". Which is why Via used a factory 4.3 as their Silverado range extender.

Windydrew

· #38 · 4 mo ago

I'm in Kansas so no emissions testing

remy_martian

· #39 · 4 mo ago

When it comes to Federal emissions law, you're not in Kansas anymore, Dorothy. Kansas assumes factory equipment.

Windydrew

· #40 · 4 mo ago

Also, was a Diesel before and had no emissions equipment. So better than what it had.

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