Thunderstruck EVCC 2.4 User manual

EVCC 2.4 Quick-Start Guide
The Electric Vehicle Charger Controller (EVCC) integrates charger CANBUS control, J1772 Level 2
charging, an BMS hea en functions. Charge parameters are configure , save in nonvolatile memory, an
use when charging to control a CAN enable charger. The EVCC connects to analog “cell loop” Battery
Management Systems (BMSs) as well as CAN enable BMSs.
Figure 1 – EVCC System Diagram
The EVCC is configure using a simple serial interface. This interface is use for configuration an
ebugging, but is not require for normal operation. Diagnostic comman s are supporte to verify proper
wiring, to trace CANBUS messages, an to retrieve charging history.
The EVCC supports the SAE J1772 stan ar . J1772 efines the physical connector an protocols use
between the charging station (known as the “Electric Vehicle Service Equipment”), an the Electric Vehicle.
The J1772 Proximity signal is use to etermine if the charger plug is present. The J1772 Pilot signal is use
to start an stop charging (by enabling an isabling the contactor in the EVSE). The J1772 Pilot uty cycle

is measure an can be use to limit charging current. “Driveaway protection” is supporte so that the EV
cannot be riven if the charge cable is still plugge in.
The EVCC supports several CAN enable chargers, inclu ing the Thun erstruck TSM2500 charger. Charge
voltage, charge current an overall charge time are controlle completely by the EVCC over the CAN
interface to the charger. A constant current/constant voltage charge curve is supporte for Lithium Batteries;
an a three phase charge cycle is supporte for Lea Aci Batteries.
The EVCC supports up to four parallel chargers for faster charging. When multiple chargers are configure ,
they are in ivi ually CAN a resse . Work is ivi e evenly between the chargers an statistics are
gathere an recor e on each charger in ivi ually.
For complete ocumentation see http://www.thun erstruck-ev.com/tsm2500-an -charge-controller.html.

The figure below shows the EVCC pinout.
A B C D E F
112V GND Ext_Ind Loop1 12V_Sw CANH
2Ignition GND Pilot Loop2 GND CANL
3GND P_Select Proximity Pac Fault OKToDrive reserved
Figure 2 – EVCC Pinout
Bringup Checklist and Troubleshooting Hints
EV nstallation
1) Connect 12V, GND, Ignition
2) Connect Proximity, Pilot, GND
3) Connect P_Select to a selector switch (an resistor array), if use
Verify Analog nputs
1) Type “measure” with no parameters to get the expecte rea ings for each analog input. Note that if there is
not a goo groun connection between J1772 groun an EV chassis groun that the J1772 rea ings will be
erratic.
2) Verify Cell Loop, using “measure loop”
a. Disconnect J1772 plug if connecte
b. Verify rea ings with cell loop open an close .
3) Verify Proximity, using “measure proximity”
a. Disconnect cell loop, if connecte
b. Verify rea ings with charger plug isconnecte , connecte , an unlocke .
4) Verify Cutback, if use , using “measure pselect”.
a. Verify rea ings with ifferent pselect switch settings.
Verify J1772
1) Connect Cell Loop to CellLoop1 an CellLoop2.
2) Plug in J1772 Plug
3) The EVCC shoul attempt to start charging (LED blinks once per secon ).
4) Assuming the CAN bus is not connecte to the charger yet, the charge cycle shoul stop after 10-15 secon s.
5) Remove 12V from Ignition, unplug the J1772.
6) Verify the “autostart” by plugging in the J1772 plug. The EVCC shoul power up an go into the Charge state.
7) For ebugging, use “trace state” to verify that the EVCC attempts to start charging if the J1772 plug is in an
the user powers up the EVCC.
Verify Charger and CAN
1) Connect Charger to J1772, connect CAN between Charger an EVCC.
2) Verify proper installation of the CAN termination resistors. Measure between CANH an CANL to verify that
the resistance of 60ohms. Remember that if the internal EVCC termination resistor is use , that it must be
powere up in or er to make this measurement.
3) Now verify that when a charge cycle is starte , that messages are exchange between EVCC an Charger.
(Use “trace charger” or “trace can” to log the messages).
4) If the pack is not yet connecte to the Charger, the charge cycle will stop after a minute.
Systems Test
1) Verify all systems functions.