I'm using a Tesla small front drive unit in a Bug. I'd like to have 2 safety features incorporated into what I'm building.

1. An OHHH Crap button - same as you'd have on a cnc machine or 3d printer to stop the system manually. I'm it's a simple "normally close" red button on the ignition wire going ...

Battery cables are 2/0 welding wire. HV wires are contained within a 2" plastic conduit in the tunnel.

20200501_153743.jpg

I drilled a 2" hole through the top of the tunnel, then welded a small section of pipe back in to reenforce the tunnel. The opposite end of the conduit comes up at the rear ...

Battery is from a 2014 Chevy Volt. Each of the modules in the picture is 100 V. Three of these are mounted in the back and 1 upfront.

The rear luggage tray and sheetmetal were removed. I added a platform of 1" tube steel. Cardboard templating to get the sheet metal shapes right. Aluminum diamond ...

Charger access is through the middle of the hood. The lid shown in the last photo is a 6 inch deck access port that's used in the boating industry. The lid screws in with 2 turns and can be easily reached from either side of the car. I'll be making a 3d printed replacement with vw logo.

Being ...

This project consists of the following components:

* 69 beetle
* Tesla Small Drive Unit
* Elcon 3.3kw Charger ( I started out with a 10kw Tesla charger and the open source board but managed to fry the charger)
* Chevy Volt DC/DC converter
* Chevy Volt Gen 1 battery pack (16kwh)

I had the boards ...

I've made my own contactor box and need to modify the High Voltage wire that delivers power to the inverter of my small drive unit. The Wire has the funky specialized ends on it going into the inverter. I need to place lugs on the opposite end.

My question is this:

I'm chopping off one end of the ...

Potentially my last question in this thread -

Can anyone confirm for me that blinking red light (one per phase) at a 1 blink per second with no relay sounds indicates I've fried my charger?

If it means something else, great. Please share.

thanks,

In one of Damien’s old videos he stated that idle power draw was around what you’re experiencing when not charging, if memory serves. You might want to walk through those old videos from a couple years ago to verify.


I agree. During a video I watched this morning, after one of his first ...

From line 1161 - does this look odd to anyone else?

If the first "if statement" resolves as true...nothing is done because it's commented out?

if (parameters.phaseconfig == 0)
{
if (modulelimcur > (dcaclim * 0.5)) //if more current then max per module or limited by DC output current ...

From line 1161 - does this look odd to anyone else?

If the first "if statement" resolves as true...nothing is done because it's commented out?

if (parameters.phaseconfig == 0)
{
if (modulelimcur > (dcaclim * 0.5)) //if more current then max per module or limited by DC output current ...

From line 1161 - does this look odd to anyone else?

If the first "if statement" resolves as true...nothing is done because it's commented out?

if (parameters.phaseconfig == 0)
{
if (modulelimcur > (dcaclim * 0.5)) //if more current then max per module or limited by DC output current ...

Could someone try changing something for me in the messages to the slaves to verify if having a bit set or not changes behavoiurs?

This bit should be related to the charger port configuration.


0utframe.id = 0x045c; // Set our transmission address ID
outframe.length = 8; // Data payload 8 ...

Could someone try changing something for me in the messages to the slaves to verify if having a bit set or not changes behavoiurs?

This bit should be related to the charger port configuration.


0utframe.id = 0x045c; // Set our transmission address ID
outframe.length = 8; // Data payload 8 ...

So I've been seeing basically the exact same symptoms as Bulletbug on 2 different chargers. I have tried adjusting the DC scaling number with no change to behaviour, but I have not yet tried changing the output charge value. I can try that in the near future.

I only have one of those ...

So I've been seeing basically the exact same symptoms as Bulletbug on 2 different chargers. I have tried adjusting the DC scaling number with no change to behaviour, but I have not yet tried changing the output charge value. I can try that in the near future.

I only have one of those chargers ...

If the DC voltage needed to be scaled to correct it, I'm thinking this implies my charger has either:
* Different CAN messaging at the power module stage or
* Different hardware for detecting voltage and current than other chargers.

Here's a picture of the tag on the charger:

Here is a can capture using the Module 3 only. Module 1 and 2 do not exhibit the additional relay clicking attempts.

Another Question: Should I see more than 1 red light on the active module at any time? I have one solid light on during our conversation. Earlier today (prior to any logs you've seen) I had all 3 modules activated and one of them flashed an additional light on as a relay click happened ...

May I clarify some assumptions I have to see if the issue may be "baked" into one of those?

From the serial output line:

Phase 2 Feebback // AC present: 1 AC volt: 248 AC cur: 27.73 DC volt: 380 DC cur: 0.00 Inlet Targ: 60 Temp Lim Cur: 15 25 26 EN:1 Flt:0 Stat:1001101

I'm assuming that:

DC ...

Another Question: Should I see more than 1 red light on the active module at any time? I have one solid light on during our conversation. Earlier today (prior to any logs you've seen) I had all 3 modules activated and one of them flashed an additional light on as a relay click happened. Additional ...

I set item 6. to 550v and termination voltage to 650v.

Reset the board with timestamp starting over.

No change to Juicebox readings.

Then Juicebox shows:
Status: charging
Current: 0.8 amps (steady, with occasional move to 0.7 amps)
AC Voltage: 247

In the serial monitor I have never seen the ...

I did have to change the DC volt scaling number (mentioned earlier) to get the voltage to report correct pack voltage. Bringing it up in case you may have not seen that mention.

With these settings:

Settings Menu
1 - Auto Enable : ON
2 - Modules Enabled : 2
3 - Can Mode : Off
4 - Port Type : 1
5 - Phase Wiring : 1
6 - DC Charge Voltage : 400V
7 - AC Current Limit : 5A
8 - CAN0 Speed : 500
9 - CAN1 Speed : 500
a - Can Debug : OFF
b - EVSE Debug : ON
t - termination ...

Interesting that your AC current at both 120 and 240V bounces between either 10.67 or 19.20 amps. I’d start with the AC current calc and work backwards. If I’m understanding correctly, AC current is back-calculated from DC current?


Something that's not shown in these logs is that I've seen ...

Interesting that your AC current at both 120 and 240V bounces between either 10.67 or 19.20 amps. I’d start with the AC current calc and work backwards. If I’m understanding correctly, AC current is back-calculated from DC current?


Something that's not shown in these logs is that I've seen ...