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Ingineer
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Leaf Number: 6969
Location: Berkeley, California
Contact: Website

A peek at the Leaf's Charger

Tue Mar 15, 2011 5:37 pm

Did some nosing around to satisfy curiosity, and here's what I found:


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With the "hump" cover removed.


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Here's the back of the Charger. You can see the water cooling lines entering from the bottom and the cooling channels in the aluminum casting.


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Here you can see they added in an EMI filter. This is not shown in the service manual. The wiring from the front of the car appears to be about 12awg. The 2 small black wires are the pilot signal from the EVSE and the handle interlock.


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The Charger is made by Nichicon.


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This is the other major thing in the "Hump". It's the Panasonic brake backup supercapacitor assembly. Very similar to what's in the Prius, only larger.

-Phil


-Phil
Easily Learn Electricity HERE! - - - - Website: http://evseupgrade.com/ - - - - Like us on Facebook: EVSE Upgrade

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mwalsh
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Leaf Number: 0213
Location: Garden Grove, CA

Re: A peek at the Leaf's Charger

Tue Mar 15, 2011 5:43 pm

Cool! Not something I'd consider doing myself, but glad you did! :D
2011 Blue Ocean SL with 76,000 miles.
2015 pack under warranty 12/30/15.
Tinted windows.
Bridgestone Ecopia 422+ tires.
L1 EVSE upgrade.
FIAMM horns.
Superbright LED lighting.
2013 sun visors.
LED shifter.
Heated seats.
GT-R map lamp lenses.
AV L2 EVSE.

derkraut
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Leaf Number: 004248
Location: San Diego vicinity

Re: A peek at the Leaf's Charger

Tue Mar 15, 2011 5:45 pm

Hey Ingineer-----thanks for the informative info. :)
Derkraut
Color: Cayenne SLE, ETEC trim
reserved: 5/15/2010
Leaf del. 6/14/2011
New Traction battery installed on 7/28/2017:

smkettner
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Location: Orange County, CA

Re: A peek at the Leaf's Charger

Tue Mar 15, 2011 5:53 pm

So then... would a replacement (6+ kw) be a do it yourself project?
1 bar lost at 21,451 miles, 16 months.
2 bar lost at 35,339 miles, 25 months.
LEAF traded at 45,400 miles for a RAV4-EV
I-Pace on order for end of 2018 delivery

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drees
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Re: A peek at the Leaf's Charger

Tue Mar 15, 2011 5:53 pm

Nice! That beefy round bar should also help stiffen up chassis a good deal, too.
'11 LEAF SL Powered By 3.24 kW Enphase Solar PV

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Ready2plugin
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Re: A peek at the Leaf's Charger

Tue Mar 15, 2011 5:54 pm

Okay, now work your magic and double the speed to 6.6!

JimK
Posts: 33
Joined: Sat Jan 08, 2011 2:42 am
Delivery Date: 22 Apr 2011
Leaf Number: 1951

Re: A peek at the Leaf's Charger

Tue Mar 15, 2011 6:00 pm

Here you can see they added in an EMI filter. This is not shown in the service manual. The wiring from the front of the car appears to be about 12awg. The 2 small black wires are the pilot signal from the EVSE and the handle interlock.


12 gage wires are bad news for a future 6.6kw charger upgrade! A wiring harness upgrade will certainly drive the cost up

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Ingineer
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Location: Berkeley, California
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Re: A peek at the Leaf's Charger

Tue Mar 15, 2011 6:07 pm

My take is that the 6.6kW upgrade would be tricky. First off, it would require 2 beefier wiring harnesses, both running the length of the car; one from the J1772 inlet to the charger (EMI filter) and one from the charger to the HV junction box. The reason is the size of these wires appears to too small to support anything larger. It might also require an upgrade to the J1772 inlet itself.

It would also require draining the cooling system and crawling under the car to disconnect the lines.

-Phil
Easily Learn Electricity HERE! - - - - Website: http://evseupgrade.com/ - - - - Like us on Facebook: EVSE Upgrade

palmermd
Posts: 2496
Joined: Fri Apr 23, 2010 3:19 pm
Delivery Date: 31 Mar 2011
Leaf Number: 1100011011
Location: Hermosa Beach, CA

Re: A peek at the Leaf's Charger

Tue Mar 15, 2011 6:15 pm

Ingineer wrote:My take is that the 6.6kW upgrade would be tricky. First off, it would require 2 beefier wiring harnesses, both running the length of the car; one from the J1772 inlet to the charger (EMI filter) and one from the charger to the HV junction box. The reason is the size of these wires appears to too small to support anything larger. It might also require an upgrade to the J1772 inlet itself.

It would also require draining the cooling system and crawling under the car to disconnect the lines.

-Phil



What VIN are you looking at? Is is preproduction or consumer? I'd be curious to see if there is larger wires in some of the most current deliveries now that they know they have to upgrade the charger.
Michael

Leaf since 31 March 2011
Driving electric since 1996


First Bar Loss
Second Bar Loss
Third Bar Loss
Fourth Bar Loss

KeiJidosha
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Delivery Date: 26 Jun 2011
Location: Simi Valley, CA

Re: A peek at the Leaf's Charger

Tue Mar 15, 2011 6:21 pm

Ingineer wrote:My take is that the 6.6kW upgrade would be tricky. First off, it would require 2 beefier wiring harnesses, both running the length of the car; one from the J1772 inlet to the charger (EMI filter) and one from the charger to the HV junction box. The reason is the size of these wires appears to too small to support anything larger. It might also require an upgrade to the J1772 inlet itself.

It would also require draining the cooling system and crawling under the car to disconnect the lines.

-Phil

I think that’s why Nissan doesn’t want to talk about a 6.6kW upgrade. It is too integrated into the design to do profitably. Throw this thing away and buy a new one. New harness, new EMI Filter, change software, teach it how to read the pilot signal. Software update to the car and carwings. Is the cooling sufficient? And dealer Labor for doing all this. You'd faint when they show you the quote.

Huge mistake not to go 6.6kW fromt he start.

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