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Open ChargePort

Discussion in 'Model S: Battery & Charging' started by Fuzzylogic, Sep 4, 2013.

  1. necho

    necho Member

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    #41 necho, Jan 26, 2014
    Last edited: Jan 27, 2014
    Yes, I have been using this one, but got it from here

    Aurel TX-SAW MID/3 V AM Sendemodule 433,92 MHz Baustein 1.8 - 3.5 V im Conrad Online Shop | 191511


     
  2. MindBender

    MindBender Bite my shiny metal ass

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    Perhaps it's worth mentioning on the github project page that the circuit board is routed for the PIC10F200 and that it is NOT suitable for the PIC12F1822 alternative mentioned in the components list. This will avoid people from purchasing 3 useless processors, possibly blowing them up and hours of defect finding.
     
  3. lolachampcar

    lolachampcar Well-Known Member

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    It is a very simple matter to download the manufacturing package for the SiLabs 400ish MHz Si4010 key fob design and have it produced. The package comes complete with a bill of materials. Polycase makes the plastic housing and rubber membrane bits.......
     
  4. Fuzzylogic

    Fuzzylogic EU Sport 359 & S94

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    #44 Fuzzylogic, Jan 29, 2014
    Last edited: Jan 29, 2014
    Thanks, i'll update the Readme. The PCB schematic already lists the microcontroller as a 10F200.

    update:
    I updated the files on Github, the Si4010 based project is now also online

    @lolachampcar
    I added your name in the Readme, as a source to get the key fob in the USA.
     
  5. MindBender

    MindBender Bite my shiny metal ass

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    I believe for the - now legacy - project, the following Element14 SKUs should be used:

    Switch
    http://nl.farnell.com/jsp/search/productdetail.jsp?sku=1555983
    Only available in numbers larger than 25.

    Battery
    http://nl.farnell.com/jsp/search/productdetail.jsp?sku=1823482
    I was unable to find a footprint compatible battery holder, so unfortunately it's a solder-on battery.

    RF-module
    http://nl.farnell.com/jsp/search/productdetail.jsp?sku=1699470
    This is the 433.92MHz version, for Europe

    Microcontroller
    http://nl.farnell.com/jsp/search/productdetail.jsp?sku=1212714

    Capacitors
    http://nl.farnell.com/jsp/search/productdetail.jsp?sku=1457655

    Capacitor
    http://nl.farnell.com/jsp/search/productdetail.jsp?sku=1907125
     
  6. MindBender

    MindBender Bite my shiny metal ass

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    Even better; I've just ordered my ready-made device, for less than a 3rd I've spent on parts so far. It seems a bit silly now to build my own... :redface:
     
  7. simonog

    simonog Member

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    MindBender: would you feel like documenting how you get from here to a finished working device? I think several of us would find it valuable and it would save us all learning separately.
     
  8. MindBender

    MindBender Bite my shiny metal ass

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    #48 MindBender, Jan 31, 2014
    Last edited: Jan 31, 2014
    Sure. I'm not going to write a full manual, but here's a step-by-step program:

    1. Get the firmware.
    You need to download the .hex file from GitHub: https://github.com/mstegen/Open-Chargeport. Navigate to 'sourcecode' and select the file 'OpenChargeport_10F200.HEX'. It will open in viewing browser where you need to right-click the button 'RAW' and select 'Save file as', or something similar, depending on your browser. The file you receive will be the compiled binary machine code that will be programmed into the PIC microcontroller.

    2. Get a circuit board.
    You can order them here: http://oshpark.com/shared_projects/l5PuyNyd. You need to order at least 3 pieces, but they're not that expensive; About $11 each.

    3. Get the parts.
    I will repeat the list from my earlier post, yet now I can confirm that these are the right components.
    Switch
    1 pcs. http://nl.farnell.com/jsp/search/productdetail.jsp?sku=1555983
    They're available only in numbers larger than 25.
    Battery
    1 pcs. http://nl.farnell.com/jsp/search/productdetail.jsp?sku=1823482
    I was unable to find a footprint compatible battery holder, so unfortunately it's a solder-on battery.
    RF-module
    1 pcs. http://nl.farnell.com/jsp/search/productdetail.jsp?sku=1699470
    This is the 433.92MHz version, for Europe
    Microcontroller
    1 pcs. http://nl.farnell.com/jsp/search/productdetail.jsp?sku=1212714
    Capacitors
    2 pcs. http://nl.farnell.com/jsp/search/productdetail.jsp?sku=1457655
    Capacitor
    1 pcs. http://nl.farnell.com/jsp/search/productdetail.jsp?sku=1907125
    I would recommend you to multiply all numbers by three, so you can populate all three boards you will receive. You will have three devices at the price of three, isn't that a bargain?

    4. Get the tools.
    If you have an EPROM programmer supporting the PIC10F200 you can skip this step.Besides a soldering iron, some solder and a small wire cutter, you also need the following:
    8-pin DIP socket
    1 pcs. http://nl.farnell.com/aries/08-3518-10/socket-dip-8way/dp/1674784
    6-pin header row
    1 pcs. http://nl.farnell.com/fischer-elektronik/sl1-025-36z/header-pin-2-54mm-36way/dp/9729038
    PICKit programmer
    1 pcs. http://nl.farnell.com/microchip/pg164130/debugger-pickit-3-icd-dspic-usb/dp/1771323
    A PICit2 will work as well, so to the PM3, the RealICE, etc. But the PICKit is cheap and it is able to supply power to the device being programmed, which I think is a big plus because it saves the hassle of hooking up a power supply.
    Some insulated wire
    5 pcs. Around 10cm each, different colours are best.

    5. Build the programming adapter.
    If you have an EPROM programmer supporting the PIC10F200 you can skip this step. If you don't, you'll need to program the PIC using it's integrated ICSP interface.
    Unfortunately the PCB isn't equipped with an ICSP port. And if you add one yourself, you won't be able to program the device because Vpp is grounded. So you will need to program the PIC before mounting it onto the board. You need the pin header, the DIP socket and the wire to construct the following adapter:
    Prog Cable.JPG
    Close-ups:
    Socket.JPG Header.JPG
    Please note that the photos show the bottom side of the socket, so the brown wire is attached to pin 8 (!MCLR/Vpp) on the side of the little notch in the socket. The header plugs into the PICKit programmer, with the brown wire at pic 1, marked by the little triangle.

    6. Program the PIC.
    - Install MPLab 8 on your PC (I'm sure it can be done with the much more recent MPLab-X, but I don't have instructions for that. You can download MPLab from Microchip for free).
    - Attach your programmer to a USB port of your PC and let it install the drivers. It should find those, after installing MPLab.
    - Put a PIC in the socket of the adapter made in step 5 and connect the adapter to the programmer.
    - Launch MPLab 8 on your PC.
    - Under the menu 'Configure' select 'configure device'.
    - In the window that appears, select 'PIC10F200' under 'Device:' and click 'OK'.
    - Under the menu 'Programmer' select 'Select Programmer' and select the type of programmer you have attached.
    - Under the menu 'Programmer' select 'Connect'. The output window 'PICKit2' tab it should now report something like:
    Found PICkit 2 - Operating System Version 2.32.0
    Target power not detected - Powering from PICkit 2 ( 5.00V)
    PICkit 2 Ready
    - Under the menu 'File' select 'Import...'.
    - In the window that appears, now select the file 'OpenChargeport_10F200.HEX' you have downloaded in step 1.
    - In the Output window 'Build' tab it should now report something like:
    Loaded C:\Users\Robert\Desktop\OpenChargeport_10F200.HEX.
    - Under the menu 'Programmer' select 'Program'. It will now start programming and verifying your device. The output window 'PICKit2' tab it should now report something like:
    Programming Target (31/01/2014 19:52:24)
    Erasing Target
    Programming Program Memory (0x0 - 0x55)
    Verifying Program Memory (0x0 - 0x55)
    Programming Configuration Memory
    Verifying Configuration Memory
    PICkit 2 Ready
    Your device is now programmed. You can repeat the last part for the other two PICs, if you have them.

    7. Populate your board(s).
    When you receive your boards, they look like this:
    Component side.JPG
    Solder side.JPG
    - File/sand off the depaneling tabs.
    - Populate the board with components and solder them into place: Low profile components first, higher later, but the battery always last. Clip off the residual leads, but don't cut into the solder joint.
    Completely finished, your board should look like this:
    Open ChargePort board.JPG
    Tips:
    - If you're building this board into a housing, you can mount the switch on the solder side, so the other components won't be in the way.
    - Don't put the PIC in a socket as this will eventually lead to poor connections.
    - Wash off the flux residue using a good PCB cleaner like this one: http://nl.farnell.com/kontakt-chemie/kontakt-pcc-200ml/cleaner-kontakt-lr-200ml/dp/2142400.
    It will give you a professional finish of the solder side:
    Solder joints cleaned.JPG

    Now go and test your device! Mine works ;-).
     
  9. simonog

    simonog Member

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    That's a terrific guide. Thank you.
     
  10. ojee99

    ojee99 Onno

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    If anyone wants to sell me a working device, whatever the price or something else in return (or join a trip on my new boat :) or good wine or.... Please let me know?!
     
  11. Fuzzylogic

    Fuzzylogic EU Sport 359 & S94

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    Wow that's an exellent guide Mindbender!

    Chargeport openers based on the si4010 chip, can be bought here Model S Chargeport Opener
     
  12. bradhs

    bradhs Member

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    Any chance you have a US version? ;)
     
  13. MindBender

    MindBender Bite my shiny metal ass

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    Thanks. Feel free to add it to GitHub or a Wiki page.
    That's the one I got; It will be delivered today. I wanted to post the URL too, but I wasn't sure if it was allowed and I didn't wat to get anybody in trouble.

    Anyway; If you can't/won't build one, but still want one, that's the one buy. Parts alone are about that price!

    - - - Updated - - -

    You can have one of mine, no charge; Just PM me where I can mail it to.
     
  14. lolachampcar

    lolachampcar Well-Known Member

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  15. uiski

    uiski Member

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    Are you gona integrate chargeport opener to Smart EVSE also?
     
  16. lolachampcar

    lolachampcar Well-Known Member

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    We need to get Chris in here. From a practical standpoint, the 4010 transmits every time a battery is installed so simply having the OpenEVSE logic board power up either the US or EU version of a 4010 based transmitter board should allow the capability.
     
  17. uiski

    uiski Member

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