Model 3 PCS Controller Support Thread

Topics concerning the Tesla front and rear drive unit drop-in board
nkiernan
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Re: Model 3 PCS Controller Support Thread

Post by nkiernan »

Have another question about one of the error codes also. Looks like I keep getting error: 38claFaulted but I can't seem to find an explanation of what this error is?

I suspect this is to do with the 12V side and possibly to do with a poor quality 12V battery. When I connect the charge cable, DC-DC starts up and the web interface reports system is putting out the required 14V. After a short period, a high pitched whine starts at low volume and gradually increases over a period of 5 to 10 seconds, before stopping...a few low volume clicks, quiet, and then the cycle starts over again. Refreshing the web interface during this shows the DC-DC shuts off, and restarts. This seems to be coming from the small PCB behind the 12V terminal block from the PCS (as in the pics below)


DSC_8469.JPG
DSC_8468.JPG
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Jack Bauer
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Re: Model 3 PCS Controller Support Thread

Post by Jack Bauer »

These Olimex wifi modules seem to be getting worse. I am working on that in parallel. Regards activating the DCDC in drive....ooops! Genius here forgot about that one:) Leave it with me a few days. I'm not up on every fault in the pcs but claFaulted is indeed generated by the DCDC so a different 12v battery would be my first port of call. What do your DCDC temperatures look like?
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nkiernan
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Re: Model 3 PCS Controller Support Thread

Post by nkiernan »

Jack Bauer wrote: Tue Sep 20, 2022 8:37 am What do your DCDC temperatures look like?
Cool, thank you :) No coolant set up for the testing yet, didn't think they were too high but maybe that could be it:

190922_PCS_003.JPG
Is it ever necessary to have different DC-DC voltages for either driving or charging? Eg: 14V while driving when more load on 12V battery, but for hours of charging with lower draw on the battery, <14V is enough?
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Jack Bauer
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Re: Model 3 PCS Controller Support Thread

Post by Jack Bauer »

Those temps are fine. Never needed different voltages myself but it would be easy to add a "DCDC DriveV" param if folks want?
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nkiernan
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Re: Model 3 PCS Controller Support Thread

Post by nkiernan »

Jack Bauer wrote: Wed Sep 21, 2022 7:39 am Never needed different voltages myself but it would be easy to add a "DCDC DriveV" param if folks want?
I thought it would be a useful option but maybe I'm over complicating it.
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asavage
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Re: Model 3 PCS Controller Support Thread

Post by asavage »

As a data point, several auto mfrs with ICE powerplants have the ECM change the alternator's charging characteristics dynamically, such as dropping the charge voltage during heavy acceleration demands, and upping it during braking.

I recall, around 2005, having to fix a no-charge situation on a by-then old Honda (I believe) by replacing the ECM. That was new tech to me, back then. Probably old hat to most, today.
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Re: Model 3 PCS Controller Support Thread

Post by P.S.Mangelsdorf »

asavage wrote: Fri Sep 23, 2022 1:13 am As a data point, several auto mfrs with ICE powerplants have the ECM change the alternator's charging characteristics dynamically, such as dropping the charge voltage during heavy acceleration demands, and upping it during braking.

I recall, around 2005, having to fix a no-charge situation on a by-then old Honda (I believe) by replacing the ECM. That was new tech to me, back then. Probably old hat to most, today.
Yeah but that's more about load on the engine than electrical load. I don't think we really need to vary the voltage from the DC-DC.
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asavage
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Re: Model 3 PCS Controller Support Thread

Post by asavage »

Well, but you could implement higher 12v charge voltage during regen. Just an example of how dynamic DC-DC could be utilized.
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Zapatero
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Re: Model 3 PCS Controller Support Thread

Post by Zapatero »

nkiernan wrote: Sat Aug 27, 2022 7:43 pm I've not connected pin 2 of the 12 pin connector and I have the V2 also. Poor photo below, I can get a clearer one if needed. All I needed to connect was pin 1 (Gnd/12V-), pin 2 (12V+), and pin 5 (Input 1 connected to 12V+ also) on the 20 way connector, then ground the PCS case. Have a 5A fuse off the battery 12V terminal too. Firmware Damien posted earlier uploaded via the web interface ok, restarted, and could see the error bits info in the web interface.


DSC_8283.JPG
Where did you get this Housing for the PCS Controller Board from EVBMW?

I need one of these :)
nkiernan
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Re: Model 3 PCS Controller Support Thread

Post by nkiernan »

Zapatero wrote: Wed Sep 28, 2022 7:01 am Where did you get this Housing for the PCS Controller Board from EVBMW?
I've had my PCS controller a while so it was before the shortage issue and I was able to get it at Mouser.co.uk I believe
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Zapatero
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Re: Model 3 PCS Controller Support Thread

Post by Zapatero »

Would you have a part number? That would be awesome! Thanks!
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Zapatero
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Re: Model 3 PCS Controller Support Thread

Post by Zapatero »

I'm still looking for a 3D printable version of this Plug.
Does this exist? Buying the cable is around 200€ - thats a lot just for a Plug!
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nkiernan
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Re: Model 3 PCS Controller Support Thread

Post by nkiernan »

Zapatero wrote: Wed Sep 28, 2022 9:17 pm Would you have a part number? That would be awesome! Thanks!
This should be the one, same as used on some of the other controllers such as the GS450H VCU. I have the dual plug version of the PCS controller

https://eu.mouser.com/ProductDetail/Cin ... cycode=GBP
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Jack Bauer
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Re: Model 3 PCS Controller Support Thread

Post by Jack Bauer »

One quick search of this thread with the term "3d print" reveals :
https://github.com/muehlpower/EV-FFB

Can someone please add to the wiki page? I have done so on the first post.
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Zapatero
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Re: Model 3 PCS Controller Support Thread

Post by Zapatero »

Jack Bauer wrote: Thu Sep 29, 2022 8:45 am One quick search of this thread with the term "3d print" reveals :
https://github.com/muehlpower/EV-FFB

Can someone please add to the wiki page? I have done so on the first post.
Correct, BUT the HV Plug that i posted above is NOT included in this List, so there is no 3D Model of this Plug so far...
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Re: Model 3 PCS Controller Support Thread

Post by asavage »

Yeah, I looked last night, and meuhlpower's page is mentioned for PCS power connectors in the wiki three times, but he doesn't have any info on that particular connector. I cleaned up a bit of verbiage in that section of the wiki while I was there.
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