Tesla Charger Support Thread

Topics concerning the Tesla front and rear drive unit drop-in board
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Jack Bauer
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Tesla Charger Support Thread

Post by Jack Bauer »

Setting up a support thread for the open source Tesla Charger controllers.
Will cover both Gen 2 and Gen 3.
Built and Tested boards available from the webshop :
http://www.evbmw.com/index.php/evbmw-we ... ted-boards
Bare PCBs for those who wish to build their own :
http://www.evbmw.com/index.php/evbmw-we ... are-boards
Github resources :
https://github.com/damienmaguire/Tesla-Charger
https://github.com/damienmaguire/Tesla-Gen3-Charger

Gen2 Charger user manual :
https://github.com/damienmaguire/Tesla- ... manual.pdf

Video manual for building the Gen 3 charger controller kit:


PLEASE READ THE THREAD OR USE THE SEARCH FUNCTION BEFORE POSTING A QUESTION. YOU WILL PROBABLY GET AN ANSWER MUCH FASTER THAT WAY :)

Here is a video detailing exactly how support works for Tesla and other logic boards from the evbmw webshop. I would encourage anyone considering a purchase to please view this video and ensure you are comfortable and familiar with the support structure around these products.


21/01/2020 : New V5 design based on the STM32F103C8T6 now released on Github.

11/10/20 : I am commonly asked about BMS support for the boards :

There is no support in the current firmware for any particular bms. However the following options are available :
- The IN1 pin can be used as a charge enable/disable input. Pull it to 12v to enable and ground to disable.
- The external CAN interface is available and could be used to receive commands from a CAN capable bms but no such features are implemented in the current firmware and I have no plans to add.

30/10/20 : For those wanting control of the 12v supply to the charger when pluging in and out, use Simpcharge :
https://www.secondlife-evbatteries.com/simpcharge.html

31/01/21 : New V3 STM32 based design for Gen 3 charger released which support the new Openinverter firmware with wifi interface :
viewtopic.php?f=10&t=1323
Sources on Github :https://github.com/damienmaguire/Tesla-Gen3-Charger
Kits now reduced by 100 euros on webshop :
https://www.evbmw.com/index.php/evbmw-w ... sla-boards
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JSJFIN
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Re: Tesla Charger Support Thread

Post by JSJFIN »

I read whole thread in diyelectriccar.com forum but i'm still not sure how to connect charger to HV battery do i need precharge or not? I have precharge contactor and +HV and -HV contactors but i was thinking to connect charger directly to HV-battery+ and when needed close -HV contactor then my inverter is not powered while charging is this right way to do this?
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Jack Bauer
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Re: Tesla Charger Support Thread

Post by Jack Bauer »

No need to precharge the charger. It does it itself during startup. Just connect with an appropriate fuse.
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martii
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Re: Tesla Charger Support Thread

Post by martii »

Jack Bauer wrote: Wed Mar 20, 2019 7:32 am Setting up a support thread for the open source Tesla Charger controllers.
Will cover both Gen 2 and Gen 3.
Built and Tested boards available from the webshop :
http://www.evbmw.com/index.php/evbmw-we ... ted-boards
Bare PCBs for those who wish to build their own :
http://www.evbmw.com/index.php/evbmw-we ... are-boards
Github resources :
https://github.com/damienmaguire/Tesla-Charger
https://github.com/damienmaguire/Tesla-Gen3-Charger
Could somebody fix above links, please? They don't work. Thanks.
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Jack Bauer
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Re: Tesla Charger Support Thread

Post by Jack Bauer »

Done!
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Chad B
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Re: Tesla Charger Support Thread

Post by Chad B »

Having trouble with Gen 3 charge controller activating charger.
12kw charger with only 2 modules US version. Controller is sending 12V+ and 5V to both modules but NO activate or enable signal.
Using Cool Term serial port terminal, setup to work without EVSE. What am I missing?
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Jack Bauer
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Re: Tesla Charger Support Thread

Post by Jack Bauer »

Assuming this is the unit I had back recently it has been confirmed working so one of three things is happening :
1) There is an open somewhere in the wiring loom between the controller and charger.
2) Something is pulling down the signals before they reach the power modules like a short.
3) The unit is improperly configured. (unlikely as it was configured to activate all 3 modules by me).

What I would do is use a bench power supply to apply 5v and 12v and enable signals to each module in turn to see if they wake up and show their red leds. Then work backward from there looking for wiring problems.
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Chad B
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Re: Tesla Charger Support Thread

Post by Chad B »

All wires from controller to modules have been ohm checked pin to pin. I have noticed once I supply 12v to the controller both charger modules red led light for about half a second then go out. Pin 3 active on charger is looking 3v, what voltage is pin 4 enable looking for?
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Re: Tesla Charger Support Thread

Post by Jack Bauer »

Ok that's a good sign. Enable is 5v.
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Chad B
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Re: Tesla Charger Support Thread

Post by Chad B »

Ok I’ll try the bench test Monday when I’m back at the shop. Thanks for the help
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Re: Tesla Charger Support Thread

Post by Chad B »

Ok so controller disconnected I applied voltage to pins of 12 way plug as follows 1 = ground, 2= 12V+, 3= 5V+
6= 3V+, 7= 3V+, 9= 5V+, 10= 5V+ and both modules red LED turn ON. CAN bus reads 121 ohms disconnected from controller and 60.5 ohms when connected to controller. So bench test seems successful.
This is the setup of my system, battery 248V connected to charger, controller parameters 1= Off, 2=123, 3=Master
4=1, 5=1, 6=280V, 7=5A, 8=500, 9=500, a=Off, b=On,
t=290V
When I apply 12V to controller the red led #2 on the controller turns on stays on and the modules leds turn on for milliseconds then turn off. I press the “s” command and LED #1 on the controller turns ON, but nothing on the charge modules happens? I’ve tried this with the AC mains (240V single phase) disconnected and connected same result. Is there a way to debug the CAN to see what the charger is saying?
Chad B
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Re: Tesla Charger Support Thread

Post by Chad B »

Does the controller look for the correct CAN messages from the charger before it sends the activate and enable signals?
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Jack Bauer
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Re: Tesla Charger Support Thread

Post by Jack Bauer »

That all sounds good. Do you have Digital input 1 (IN1) pulled up to 12v? This is the charger enable signal.
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Chad B
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Re: Tesla Charger Support Thread

Post by Chad B »

Know I do, looks like it’s active now. I’m going to connect to a 400V battery will see how it does. What is the low voltage dc limit of this charger? Thanks for the help
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Jack Bauer
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Re: Tesla Charger Support Thread

Post by Jack Bauer »

Don't go under 200v DC.
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jklafehn
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Re: Tesla Charger Support Thread

Post by jklafehn »

Hello,

I am installing a gen 2 Tesla charger using one of your boards. I have a couple questions.
1. I am wondering where I should place fuses. On the charging plug side or the battery side?
2. What fuses/holders do you recommend? Links?
3. Can you post a pinout for the harnesses on a Tesla Gen 2 charger?

Thank you!
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Re: Tesla Charger Support Thread

Post by Jack Bauer »

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jklafehn
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Re: Tesla Charger Support Thread

Post by jklafehn »

Chad B wrote: Sat Apr 13, 2019 4:27 pm Ok I’ll try the bench test Monday when I’m back at the shop. Thanks for the help
I just read it. Very useful thank you!

It doesnt mention fuses though. Shouldnt I use some? If so, is there a type you recommend and location? AC side or DC side? Both?
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Kevin Sharpe
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Re: Tesla Charger Support Thread

Post by Kevin Sharpe »

jklafehn wrote: Mon Apr 29, 2019 1:24 pm
Chad B wrote: Sat Apr 13, 2019 4:27 pm Ok I’ll try the bench test Monday when I’m back at the shop. Thanks for the help
It doesnt mention fuses though. Shouldnt I use some? If so, is there a type you recommend and location? AC side or DC side? Both?
Tesla don't use any fuses on the AC input (the charging station will take care of this function). Tesla have one main fuse in the battery (450A on 'standard' cars iirc) and nothing extra on the charger DC output. We just followed Tesla's example and didn't add any extra fuses for the charger AC or DC :)
This is a personal post and I disclaim all responsibility for any loss or damage which any person may suffer from reliance on the information and material in this post or any opinion, conclusion or recommendation in the information and material.
jklafehn
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Re: Tesla Charger Support Thread

Post by jklafehn »

Kevin Sharpe wrote: Mon Apr 29, 2019 4:40 pm
jklafehn wrote: Mon Apr 29, 2019 1:24 pm
Chad B wrote: Sat Apr 13, 2019 4:27 pm Ok I’ll try the bench test Monday when I’m back at the shop. Thanks for the help
It doesnt mention fuses though. Shouldnt I use some? If so, is there a type you recommend and location? AC side or DC side? Both?
Tesla don't use any fuses on the AC input (the charging station will take care of this function). Tesla have one main fuse in the battery (450A on 'standard' cars iirc) and nothing extra on the charger DC output. We just followed Tesla's example and didn't add any extra fuses for the charger AC or DC :)
Wow I didnt know that. Thanks for the info! Saves me some money and time!
tom91
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Re: Tesla Charger Support Thread

Post by tom91 »

Contrary to that, the chargers are fused.

see the High Voltage Junction Box
Image

Kevin you even uploaded the PCB schematic yourself.

You should always fuse an HV source, so if your charger can produce HV fuse it.

You should place the fuse near the source and to protect the wiring, so if you run a thin cable from your battery, fuse it at the battery as a battery can deliver alot more current. Officially you should then also fuse it at the charger to be extra careful.

Saving time and money should not be your going in point when designing and specifying your HV system. Always design a fail safe system. (btw chargers have output fuses on them you do not want those going when there is an issue as there are none replaceable),
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Kevin Sharpe
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Re: Tesla Charger Support Thread

Post by Kevin Sharpe »

tom91 wrote: Mon Apr 29, 2019 7:21 pmKevin you even uploaded the PCB schematic yourself.
Amazing what you forget :) Thanks for correcting my error... at some point we need a schematic for an Open Inverter based car 8-)
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swoozle
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Re: Tesla Charger Support Thread

Post by swoozle »

What kind of charger temps are folks seeing in normal operation?

At what temp does it start reducing the current?

Thanks
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Jack Bauer
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Re: Tesla Charger Support Thread

Post by Jack Bauer »

So for fusing on the gen 2 charger DC side what I would recommend is a 20A fuse on the B+ of each phase. The type is rather important as DC fault current is much harder to rupture then AC. Fortunately, Solar PV fuses are ideal. Here is an example.
https://ie.rs-online.com/web/p/cartridge-fuses/7546294/

The AC side is best handled by a circuit breaker rated for the supply voltage of your region and rated at 20A per power module.
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Re: Tesla Charger Support Thread

Post by Jack Bauer »

I rarely see temps of over 45C on the modules. Not sure where derating starts but I'll look it up and post on here in a few days.
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