DCFC Troubleshooting

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MMONTERO

New member
Joined
Aug 24, 2021
Messages
2
Hi!

I have an Spark EV 2016 with DCFC, car works great, no issues.

Before I brought the car to Costa Rica, the car charged fine with DCFC in USA. In Costa Rica, none of the Spark EVs that are here are able to DCFC.

The chargers over here are TELLUS, MAGNUMCAP and CIRCUTOR brands. We have no ABB or name brands.

Please find attached below a charge log, some of you may know how to troubleshoot this already and could help me.

https://drive.google.com/file/d/1AtXXQfjnOxNRUiAO7l9t20gWotaxFHLx/view?usp=sharing

I am in contact with the technicians that installed the chargers and they have no idea of what to do. I am an electronic engineer and have experience with PLCs and automation but until now zero experience with EVSE.

Thanks!

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Hello, MMONTERO!

I also am not familiar with reading the PLC logs but we can give it a try.

Have you tried DCFC on any other stations besides this one? What do you mean by "none of the Spark EVs that are here are able to DCFC." Are you saying you've spoken to owners in Costa Rica with DCFC and they have the same issue?

Can you take a close-up picture of your charge port, specifically at the top where the retaining lock is? I'd like to see if your vehicle has the chamfer on the walls that guide the latch into the locking well, if you will. If not, the J1772 SAE combo connector may not mate with the receptacle correctly, especially under the weight of heavy liquid-cooled cables, and you might be faced with possible continuity issues. for communication and/or power.

see https://sparkev.blogspot.com/2015/09/solution-problem-with-dc-fast-charge.html?m=1 on this issue. Although you say it DCFC'd fine in the USA, it's worth making sure.

See the following link for the J1772 SAE combo diagram:
https://weberstate.app.box.com/s/wcksjm6j80ubrqdqkqr8sy8o6vhlgr0t

Contact #3,#4, and #5 must have proper contact for connection detection in the case of contact #5, and the control pilot and 1kHz PWM signal for charge control in the case of contact #4. If there is dirt and grime built up in these connectors it could cause issues, so spraying an electronics connector-friendly aerosol cleaner would be a good idea to use for clearing away debris, or compressed air. An O2 sensor cleaner or electronics-grade isopropyl alcohol could be a substitute.

If we get the following lines:
10/12 05:05:51.428 [INFO] CAN: WF_PLUGGED_IN (1), CMD = 3
10/12 05:05:51.466 [NONE] plug trigger:pLUGIN
10/12 05:05:51.487 [NONE] pwm trigger:OFFLINE
10/12 05:05:51.508 [NONE] voltage= 8.96
10/12 05:05:51.530 [NONE] dutycycle = 100

Then we can say that Earth ground and proximity detection through contact #5's pull-down resistor in the car are making contact and functioning, great. We know this because 8.96V DC (100% duty) indicates a pull-down resistance of around 2740Ω which is part of the J1772 standard. This can be confirmed in the service manuals as well as on Wikipedia here https://en.wikipedia.org/wiki/SAE_J1772#Control_Pilot

Next, we get a PWM trigger

10/12 05:06:05.016 [NONE] plug trigger:NONE
10/12 05:06:05.037 [NONE] pwm trigger:HLC
10/12 05:06:05.058 [NONE] 10/12 05:06:05.065 [INFO] Got EVENT (0x8)
10/12 05:06:05.065 [INFO] Get IEC61851 EVENT:DB_EVTMASK_IEC61851_PLUG_EVENT(8)
voltage= 8.92
10/12 05:06:05.079 [NONE] dutycycle = 6

In other words the car is sending a PWM signal to the station now and the station is loading or establishing the IEC 61851 charge protocol for what is probably a J1772 SAE combo connection and not a CHAdeMO protocol. This 61851 should be the protocol used in the USA and internationally for slow and fast AC charging with J1772, and DCFC https://en.wikipedia.org/wiki/IEC_61851

We can also see from the Tellus Power charger spec sheet matching in your photo, that IEC 61851 is being used:
http://telluspowergreen.com/wp-content/uploads/2021/08/CE_TPG_160kW_Specs.pdf

Things seem to be going fine until:
10/12 05:06:08.185 [INFO] <-- CM_SLAC_MATCH.REQ
10/12 05:06:08.092 [ERR] invalid MVFLength, will be ignored.

10/12 05:06:17.567 [ERR] timeout wait for VALIDATE.REQ or MATCH.REQ (0)

some time goes by...

10/12 05:06:31.981 [INFO] Got EVENT (0x0)
10/12 05:06:31.988 [ERR] Failed to get data ready, touch gbt27930.
And this is really weird, because GB/T 27930 is the Chinese standard for DCFC. Why is that being referred to here?

After that, it cancels the charging session and reverts contact #4 control pilot state back to an earlier state...

10/12 05:06:32.121 [NONE] data_link : bem error & bem EV error & goto GBT27930_ERROR_PROC !--BEM_ErrorCode=32,BEM_EvErrCode=0

Then things get a little crazy from here since the station is referring to GB/T 27930 and claims the control pilot state is illegal as I assume it is now speaking in CAN rather than PLC as the China GB/T standard communicates with CAN and CCS1 uses PLC.

05:06:33.262 [ERR] 10/12 05:06:33.264 [NONE] CHM cause to CEM error & goto GBT27930_ERROR_PROC

At least that is my interpretation of the logs.

Maybe the accidental switch to GB/T is due to the heavy cables pulling down on the connector in the spark's charge port receptacle, or maybe something is up with the charging station that it switches from a happy IEC61851 event to a very wrong GBT27930. It would be interesting if you could visit another DCFC station to see if this issue persists. Maybe support the connector firmly by hand to see if charging actually begins. If it does, maybe see to modifying the shape of the plastic in front of the latch.

Hope we can get more info. Please correct me on any of my interpretations if you think they are wrong.
 
Infinion gave great advice and lots of wonderful information. I am very new to the Spark EV world and this is my first post. The only thing I could add is to check your 12 volt battery. Make sure it is good and is a ACDelco LN1AGM. I have heard many times that a weak 12 volt battery or the wrong kind of 12 volt battery can cause many issues. It is always best to use what the original manufacturer used. In this case it be the ACDelco LN1AGM.

I just did the modification on the car's charge port as Infinion's link described. https://sparkev.blogspot.com/2015/09/solution-problem-with-dc-fast-charge.html?m=1 I then went to an Electrify America charger that in the past I just couldn't get to work. It kept giving me an communications error. I am happy to say after the modification it worked on the first try and charged my car at 50 kW. I have a 2014 Spark EV. As far as I know the 2016 Spark EVs charge port was changed to correct the problem. Definitely check the link and compare the photos with your own car's charge port.
 
Recent threads / posts on slow DCFC charging for Spark EV :

https://www.mychevysparkev.com/forum/viewtopic.php?p=28560

https://www.mychevysparkev.com/forum/viewtopic.php?p=28561

https://www.mychevysparkev.com/forum/viewtopic.php?p=28562

https://www.mychevysparkev.com/forum/viewtopic.php?f=6&t=9270&p=28539#p28539
 
Sorry to revive an old thread, but was there ever a resolution to this? Also, how was this log collected, from the charger or the car? I'm trying to figure out why the spark seems to not work on some newer chargers, and I'm wondering if it's something with the communication protocol.
 
Sorry to revive an old thread, but was there ever a resolution to this? Also, how was this log collected, from the charger or the car? I'm trying to figure out why the spark seems to not work on some newer chargers, and I'm wondering if it's something with the communication protocol.
I want to know too. It would be helpful to dig into it.

I have a strong feeling the logs were given by the DCFC tech support to the user after they shared their charge session ID, where the user could then share these logs to the OEM dealer to troubleshoot or replace modules.

Otherwise the PLC communication would need to have its these messages in ASCII translated by the HPCM2 and recorded by an OBD service tool that can communicate directly to the HPCM2, read the messages as they come and store them on file. I'm not aware of anything like that, but people have used CAN sniffers in the past. Maybe the OBD port is capable of that, IDK.

https://www.charin.global/media/pag.../design_guide_combined_charging_system_v7.pdf
Very detailed design guide that covers the handshake and protocols

https://github.com/uhi22/pyPLC
CCS hacking: Electric car charging experiments with Python and PLC network adaptors

https://github.com/endland/sniffer-iso15118vse
In this project, we extend the Wireshark packet analysis tool to capture the management frames of SECC and EVCC in the air and display the contents of VSE of EVCC and SECC in the Wireshark packet analyzer to help developers of ISO 15118 to easily monitor the association procedure between EVCC and SECC for debugging and testing purposes.
https://www.wireshark.org/

So you can employ a PLC listener/sniffer on the control pilot line, and it will translate the data into ethernet packets -> ascii, or you can use a network analyzer and intercept broadcast info.

https://0e190a550a8c4c8c4b93-fcd009...r-ev-charging-communication-diagnostics-1.pdf

https://www.vector.com/int/en/products/products-a-z/hardware/vh5110a/#
https://www.keysight.com/us/en/product/SL1556A/ccs-charging-protocol-tracer.html

For $700-$1200 I can't imagine anyone who isn't already a career EVSE equipment technician to have one of these and not be able to solve their own problems. They'd have no reason to ask owners when they are the ones decked out with special tools.

I'm trying to figure out why the spark seems to not work on some newer chargers, and I'm wondering if it's something with the communication protocol.

Might be worth keeping track of your charging session ID's and getting additional data from the different charging companies' tech support
 
Sorry to revive an old thread, but was there ever a resolution to this? Also, how was this log collected, from the charger or the car? I'm trying to figure out why the spark seems to not work on some newer chargers, and I'm wondering if it's something with the communication protocol.
Something you must be made aware of is that the Chevy Spark EV was the first production EV that was equipped with CCS 1 connector. Now I don't know if the whoever manufactured the CCS 1 connector for the Spark EV didn't read the blueprints correctly or if what was finally adopted as the official physical form of the CCS 1 connector changed afterwards.

Spark EVs having problems with communicating with DC Fast Chargers has been known and understood for a long time now. Chevy even put out a service bulletin with instructions how to fix the Spark's CCS 1 connector so it is in compliance with the current CCS 1 standards. All that needs to be done is a little bit of filing down of two plastic corners. If these corners have not been filed down then the DCFC connector can't make good contact of the communications wires. Thus causing the charging attempt to fail.

I was having all sorts of problems at a number of different public charging stations. Even between different chargers at the same location. After I did the modification myself following the instructions my failure rate when down dramatically. Now when a charging attempt fails it is the DCFC that is to blame. Yes, there are still some older chargers out there that will limit the charging speed a bit but those are become fewer and farther between as they get replaced. EVgo chargers used to limit my charging speed but they eventually updated the software and that hasn't been a problem for well over a year and a half.

Anyway, here is a link to the documentation on how to make the modification. Look at the photos and then look at your Spark's charging port to see if the modification has already been done. If it hasn't follow the instructions very carefully or take it into a Chevy dealership to have it done. It shouldn't take them more than 15 minutes to do it. Took me 30 minutes but that was because I was super careful. https://sparkev.blogspot.com/2015/09/solution-problem-with-dc-fast-charge.html?m=1

Now if you have done the modification or it has already been done on your Spark there are a few things you can try if you are still having a problem at a DC Fast Charger. If it is Electrify America charger after you plug in your Spark wait till the charger is done communicating and the screen on the DCFC has gotten to the point where it is asking you to input a credit card or select a payment type. Then using the Electrify America app swipe begin charge. The other thing I read, but could never verify, is if your phone or other device is connected to the bluetooth system of the car that this can cause a problem when attempting to charge. So disconnect them from your Spark and try starting a charge.

Please let us know how things work out for you and what made the difference.
 
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Something you must be made aware of is that the Chevy Spark EV was the first production EV that was equipped with CCS 1 connector.

You have to stop telling people to file down their CCS ports. There are a few instances where an unmodified port from an early spark caused chargers to not latch in properly. However the issue in most cases is software. As you say, it was the first vehicle with a CCS port, and the handshake protocol seems to be picky. That is what is being discussed here.
 
You have to stop telling people to file down their CCS ports. There are a few instances where an unmodified port from an early spark caused chargers to not latch in properly. However the issue in most cases is software. As you say, it was the first vehicle with a CCS port, and the handshake protocol seems to be picky. That is what is being discussed here.
 
I have a 2014 Spark and the are definitely issues with the physical connection to the charging port when using DC fast chargers. I saw an improvement for a while after I filed down the recommended part of the charging port. Now I need to put some upward pressure on the handle of the charging cord while the charge is initializing. Once the charge begins I can release the handle and it continues to charge.
 
I really agree with Randy, I've not filed down any plastic on my Spark but have learned to hold the E.A. BTC branded DCFC units on an slight tilt while watching the connectors like a hawk. I almost always get a successful charge however when I use the newer EvGO Delta Electronics units (they feature CCS/CHA-De-Mo/Tesla connectors), they don't even attempt to energize any connectors before they fail on the DC Fast Charger screen. I therefore am far from convinced that filing of plastic will do any good.
 
Just to keep this thread going. Has anyone tried plugging any of the A2Z NACS-to-CCS1 adapters into their Spark EV at a Evgo Delta Electronics NACS equipped DCFC?
I don't know of any of those around me, but New York has been rebuilding the rest stops along 90, and the closest one has Signet chargers with CCS and NACS. I've been thinking about trying the chargers, especially since I can try the same units with CCS and a NACS adapter.
 
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