THUNDERSTRUCK 24292668 Lear Hi-V Charger User Guide
- June 3, 2024
- THUNDERSTRUCK
Table of Contents
24292668 Lear Hi-V Charger
User Guide
24292668 Lear Hi-V Charger
The Lear High Voltage Charger is a CAN-controlled charger removed from
production Coda EVs. It can charge battery packs of 200 to 420 VDC with 120VAC
or 240VAC input. It has a maximum output current of 11A and maximum power
output of 3300W and is liquid-cooled. The Lear charger may be controlled using
charge controllers from Thunderstruck (e.g. the Dilithium MCU and EVCC). This
charger looks identical to Chevy Volt chargers, but has unique canbus and
connection requirements.
The MCU and EVCC kits include canbus wires and a 120-ohm resistor, which is
used if tests show it is needed for CAN functionality. Note that the Lear
charger has a CAN data rate of 500kbps. The charge controller must be
configured for this canbus rate.
Connections required for installation
-
12V Connections (connector to the right)
Connect Pin A to +12V power.
Connect Pin F to +12V power.
Connect Pin G to 12V ground. -
EVCC CAN Connection (connector to the right)
Pin B – CANH.
Pin C – CANL.
120-ohm resistor across CANH and CANLnear connector (if needed). -
120VAC or 240VAC Input Power (3-wire connector)
(Connector: Orange Delphi 13861587)
Facing the connector on the charger in the figure: The ground is the middle pin; other wires are lines. -
200-420VDC Output (2-wire connector)
(Connector: Orange Delphi 13861585)
Facing the connector on the charger in the figure: Right-hand side: Positive, left-hand side: Negative.
Configuring the Charge Controller for Lear Charger
To configure the MCU or EVCC, a device with terminal software must be used.
To find the software, go to https://www.thunderstruck-ev.com/chargers-ev/.
The MCU and EVCC links on this page provide many resources including user
interface software, manuals and tutorials. A list of applicable controller
parameters is shown below, with significantly more information included in the
online manuals.
Charger Type: Use the command set charger lear Canbus
Data Rate: To set the data rate, use the command:
- MCU: set can1br 500 or set can2br 500
- EVCC: set canbr 500
Maximum Voltage: Set your maximum charging voltage here. For example,
enter set max 380 to set the maximum charging voltage to 380V.
Maximum Current: The Lear charger can only output maximum current,
relative to what is available from the AC input. The EVCC will disregard the
max, so the value of the max is not important.
Line Current: The Lear charger receives CANbus commands for AC input
current, so a line set is required for it to operate. If using J1772, enter
set line j1772 to get the maximum line current that the charging handle can
supply. Otherwise, line current can manually be set. For example, if you want
to set the line current to 15A, enter set lines 15. Line Voltage: Line
voltage can also be manually set by entering set line 120 or set lines 240
This is not needed if using J1772.
Battery Management System: When using the EVCC, the BMS can be set to
basic, none, loop, or loop and bass. See the complete EVCC manual for more
information on configuring for BMS. The MCU includes BMS settings within its
user interface.
Troubleshooting Notes: Reports show the following suggestions may help for
troubleshooting:
- Check the controller canbus baud rate – must be 500 kbps.
- Note that wire colors may vary between installations – use connector pin letters for identification. The diagram above shows the inside of the connector on the charger side.
- The two-pin connector (aux. 12v output) does not need to be connected for operation.
- Ensure that the charger case is grounded to 12v negative when using J1772 EVSEs.
- If there is no can communication, check canbus Hi/Lo orientation.
- Check the connector terminals for continuity – poor connections have been reported.