TrueSoln
Posts: 8
Joined: Wed Feb 12, 2020 5:20 pm

Power Delivery Module (PDM) aka the DC-DC Converter/Junction box on Nissan Leaf Gen1 (wiring info)

Wed Feb 12, 2020 5:50 pm

This is the Power Delivery Module (PDM)
aka the DC-DC Converter/Junction box on Nissan Leaf Gen1
Part #EM57

Trying to work out how the DC/DC junction box (converter) works
So can use in own EV project
As it has the High voltage to 12v to keep the car battery side alive when in use
Plus the switching links for the HV in from battery and HV out to battery.
And quick charge and slow change links all in it.

So this is the box and where the High Voltage comes in and goes out for battery and inverter
Image

Based on the manuals, I was able to try and get idea of the control wires that go in to it.
Image

So have two plugs that need to control
Were the manual was no that helpful as showed boxes with no info in them
So I used above wire diagram to work out where they went
Image


Starting with connection of the 12v lead back to battery
And then GND the case back to battery - terminal

Then referring to plugs F11 & F12
Terminal #3 #11 would need +12v for Battery power supply
And then I was guessing that I would power up the #5 the high voltage cable interlock

But I tried this and did not get any voltage out of High Voltage to inverter ;-(

When you turn on the relays in the battery you hear them engage (with a click)
So so would expect some click also when turing on the DC to DC between the battery and inverter connection

So can any one confirm the wiring out of this box and how can connect it up please


13 Feb 2020 Update:
Pin #1 needs a PWM signal to it
Seem with that and +12 connected to pin #3 you can control the voltage that you 12v battery gets charged at
(Not sure how to make this PWM signal yet, any one have knowledge about creating the signal)

In video he talks about charging voltage
https://youtu.be/ipEzK1yzxHY?t=6723

He says
Min Voltage was 13.04 volts
Max was 15 volts

20% duty cycle is 15v
50% duty cycle is 14v

I think I recall it ranges up to 80% the higher the duty cycle goes the lower the voltage out put will be

So you might want to put some limits on your code
To go from 20% to 80% max

----------------------------------------------------------------------------------
15 Feb 2020 Update:
Worked out that HV battery to HV battery is not switch in junction box as thought
Just was not measuring incorrectly, as is a inter lock on the HV out (to inveter) so meant when tested I was reading zero volts

----------------------------------------------------------------------------------
16 Feb 2020
Managed to get the charging of DC aux battery now
And have main wire info now for the box or leads
Image
If you get #1 live
Then it starts charging,
Not sure the PWM signal needed as when it was liven up started to charge
May have a default, and the PWM can set the desired value


Thanks to Kenny, who pointed out a diagram in the EVC.pdf manual
It shows more of the wiring at high level and can see how its wired up now
Image
Last edited by TrueSoln on Tue Feb 18, 2020 2:07 am, edited 7 times in total.

TrueSoln
Posts: 8
Joined: Wed Feb 12, 2020 5:20 pm

Re: DC-DC Converter/Junction box wire mapping and understanding (Gen1)

Fri Feb 14, 2020 11:18 pm

Been testing more, and found that is not any relay in for HV leads
Just need to make sure the HV interlock connected else no Volts out.
Not sure how that works though as seem to be able to get HV out with out any power to DC/DC box

TrueSoln
Posts: 8
Joined: Wed Feb 12, 2020 5:20 pm

Re: DC-DC Converter/Junction box wire mapping and understanding (Gen1)

Sat Feb 15, 2020 12:10 am

This guy show the control the the DC charging of 12v battery using UNO
https://www.youtube.com/watch?v=NJq6gt5YG_E

TrueSoln
Posts: 8
Joined: Wed Feb 12, 2020 5:20 pm

Re: DC-DC Converter/Junction box wire mapping and understanding (Gen1)

Sat Feb 15, 2020 1:57 am

This is another great video to watch on DC/DC talks about control of voltage to AUX battery (+12 car battery)
https://youtu.be/ipEzK1yzxHY?t=6424

kiev
Posts: 1093
Joined: Sun May 03, 2015 7:15 am
Location: The Heart o' Dixie
Contact: Website

Re: DC-DC Converter/Junction box wire mapping and understanding (Gen1)

Sat Feb 15, 2020 5:58 am

i have an On Board Chargger that i traced the circuit boards, but don't have a DCDC junction box. That is a good finding about needing to vary the duty cycle of the square wave oscillator to control the LV output. i was thinking an arduino board such as UNO could be used to easily do this, or an analog op amp oscillator circuit with PWM.

Image

When i was driving a Laef i noticed that the aux battery wasn't being charged properly by the DCDC, it was running at 13.0 most of the time. Except when you turned on the wipers, then it went up to 14.4 V.

Here is a top level diagram of the VCM for 2011 if it might help

Image
Last edited by kiev on Sat Feb 15, 2020 5:42 pm, edited 3 times in total.
kiev = kenny's innovative electric vehicle

TrueSoln
Posts: 8
Joined: Wed Feb 12, 2020 5:20 pm

Re: Power Delivery Module (PDM) aka the DC-DC Converter/Junction box on Nissan Leaf Gen1 (wiring info)

Sat Feb 15, 2020 4:17 pm

@kiev where is the diagram from please.
Did you know the work shop manual pdf name and page number?

I want to work out the charging next also.
Have the onboard unit and wiring and want to see if can charge it up

kiev
Posts: 1093
Joined: Sun May 03, 2015 7:15 am
Location: The Heart o' Dixie
Contact: Website

Re: Power Delivery Module (PDM) aka the DC-DC Converter/Junction box on Nissan Leaf Gen1 (wiring info)

Sat Feb 15, 2020 5:36 pm

That was in the 2011 EVC manual, pages 25-26. i didn't make one for 2012, but i found the manuals at this web site

https://carmanuals2.com/brand/nissan/leaf-2012-372
kiev = kenny's innovative electric vehicle

TrueSoln
Posts: 8
Joined: Wed Feb 12, 2020 5:20 pm

Re: Power Delivery Module (PDM) aka the DC-DC Converter/Junction box on Nissan Leaf Gen1 (wiring info)

Sat Feb 15, 2020 7:11 pm

@Kenny thanks,
Found in the manuals

Also found
about page 40 is "LI-ION BATTERY CHARGE CONTROL : Normal Charge Control"
and about page 42 is "LI-ION BATTERY CHARGE CONTROL : Quick Charge Control"

They show images of wires and data flow for charging it on board charger and the fast charger.
So will have to look at these manuals and see what need and work out how to power up charger.

I did manager to get AUX charging, but not work out controlling it with UNO yet.

TrueSoln
Posts: 8
Joined: Wed Feb 12, 2020 5:20 pm

Re: Power Delivery Module (PDM) aka the DC-DC Converter/Junction box on Nissan Leaf Gen1 (wiring info)

Sun Feb 16, 2020 7:52 pm

In video he talks about charging voltage
https://youtu.be/ipEzK1yzxHY?t=6723

He says
Min Voltage was 13.04 volts
Max was 15 volts

20% duty cycle is 15v
50% duty cycle is 14v

I think I recall it ranges up to 80% the higher the duty cycle goes the lower the voltage out put will be

So you might want to put some limits on your PWM
To go from 20% to 80% max, or just set to 50% to stay at 13v

TrueSoln
Posts: 8
Joined: Wed Feb 12, 2020 5:20 pm

Re: Power Delivery Module (PDM) aka the DC-DC Converter/Junction box on Nissan Leaf Gen1 (wiring info)

Tue Feb 18, 2020 1:54 pm

TrueSoln wrote:This is the Power Delivery Module (PDM)
aka the DC-DC Converter/Junction box on Nissan Leaf Gen1
Part #EM57

Trying to work out how the DC/DC junction box (converter) works
So can use in own EV project
As it has the High voltage to 12v to keep the car battery side alive when in use
Plus the switching links for the HV in from battery and HV out to battery.
And quick charge and slow change links all in it.

So this is the box and where the High Voltage comes in and goes out for battery and inverter
Image

Based on the manuals, I was able to try and get idea of the control wires that go in to it.
Image

So have two plugs that need to control
Were the manual was no that helpful as showed boxes with no info in them
So I used above wire diagram to work out where they went
Image


Starting with connection of the 12v lead back to battery
And then GND the case back to battery - terminal

Then referring to plugs F11 & F12
Terminal #3 #11 would need +12v for Battery power supply
And then I was guessing that I would power up the #5 the high voltage cable interlock

But I tried this and did not get any voltage out of High Voltage to inverter ;-(

When you turn on the relays in the battery you hear them engage (with a click)
So so would expect some click also when turing on the DC to DC between the battery and inverter connection

So can any one confirm the wiring out of this box and how can connect it up please


13 Feb 2020 Update:
Pin #1 needs a PWM signal to it
Seem with that and +12 connected to pin #3 you can control the voltage that you 12v battery gets charged at
(Not sure how to make this PWM signal yet, any one have knowledge about creating the signal)

In video he talks about charging voltage
https://youtu.be/ipEzK1yzxHY?t=6723

He says
Min Voltage was 13.04 volts
Max was 15 volts

20% duty cycle is 15v
50% duty cycle is 14v

I think I recall it ranges up to 80% the higher the duty cycle goes the lower the voltage out put will be

So you might want to put some limits on your code
To go from 20% to 80% max

----------------------------------------------------------------------------------
15 Feb 2020 Update:
Worked out that HV battery to HV battery is not switch in junction box as thought
Just was not measuring incorrectly, as is a inter lock on the HV out (to inveter) so meant when tested I was reading zero volts

----------------------------------------------------------------------------------
16 Feb 2020
Managed to get the charging of DC aux battery now
And have main wire info now for the box or leads
Image
If you get #1 live
Then it starts charging,
Not sure the PWM signal needed as when it was liven up started to charge
May have a default, and the PWM can set the desired value


Thanks to Kenny, who pointed out a diagram in the EVC.pdf manual
It shows more of the wiring at high level and can see how its wired up now
Image


19 Feb 2020
Uploaded video of getting it to charge.
Image

Return to “Batteries and Battery Management”