Tesla Model 3 Charger

[fredd90]

Fantastic work, I am very impressed with your quick problem solving.

I myself have a little smaller project in the pieline, as I want to use the original tesla m3 hv contactor.

I have ordered some stuff from TI.com so I can put together an economizer circuit for the coil. Should be based on a DRV110, I hope I manage to put together something usable. https://www.ti.com/product/DRV110https://www.ti.com/tool/DRV110EVM

[Jack Bauer]

Now in production at JLCPCB

[FJ3422]

...Should be based on a DRV110, I hope I manage to put together something usable. https://www.ti.com/product/DRV110https://www.ti.com/tool/DRV110EVM

Went the same route. My pittfalls seemed to be:

- When using a low-side protected-mosfet, find one that is capable of doing 20KHz (most are not).
- My contactors seem to have a small capacitor across the coil. This disturbs the current measurement of the DRV110 (immediately limits at the initial pulse) and thus the current regulation. That's the reason behind the RC-network parallel to the sense-resistor.
- Don't forget the pull-down at the enable-input when driving from a CPU. The DRV110 has an internal pull-up, so when the CPU-output floats (at boot) is will activate all contactors .
- Really test with the contactors wou want to use, measure current feedback with an oscilloscope and adjust the RC-network to avoid hissing sounds from the contactor and a stable pulsewidth.

JLC doesn't stock the DRV110, so I manually add them only to the outputs that I use for contactors. Solderjumper is to use the FET as a normal output when the DRV110 is not present.

How I ended:

[fredd90]

...Should be based on a DRV110, I hope I manage to put together something usable. https://www.ti.com/product/DRV110https://www.ti.com/tool/DRV110EVM

Went the same route. My pittfalls seemed to be:

- When using a low-side protected-mosfet, find one that is capable of doing 20KHz (most are not).
- My contactors seem to have a small capacitor across the coil. This disturbs the current measurement of the DRV110 (immediately limits at the initial pulse) and thus the current regulation. That's the reason behind the RC-network parallel to the sense-resistor.
- Don't forget the pull-down at the enable-input when driving from a CPU. The DRV110 has an internal pull-up, so when the CPU-output floats (at boot) is will activate all contactors .
- Really test with the contactors wou want to use, measure current feedback with an oscilloscope and adjust the RC-network to avoid hissing sounds from the contactor and a stable pulsewidth.

JLC doesn't stock the DRV110, so I manually add them only to the outputs that I use for contactors. Solderjumper is to use the FET as a normal output when the DRV110 is not present.

How I ended:

Interesting, I have already had time to sketch a bit on components and it is as you say, difficult to find fast switching n-channel mosfet.

Good idea regarding pulldown resistor, easy to forget
My plan is to buy a loose hv-contactor and experiment with it, it draws about 8-9A in startcurrent so the mosfet needs to be quite solid.
I have found this one on Elfa: https://www.elfa.se/en/automotive-mosfe ... opup=false
Continuous drain 20A @ 40v. and 20-25ns at full amp

I bought the drv110 experiment board to make things easy but the included mosfet maxed out at 1A unfortunately, just wait for the new mosfet.

I have no idea if my contactors are equipped with a condensator, hope not

[Jack Bauer]

Please start a new thread if you wish to discuss something off topic.

[Jack Bauer]

PCS controllers have arrived and almost at a full power test:)

[nkiernan]

Nice, looking good

Would you envisage the Model 3 charger, BMS and charge port controller work being integrated to a single controller in future or preferable as separate controllers?

[Jack Bauer]

Got some time this morning to build up a controller and start testing. DCDC side works but no output from charger. traced to a simple software issue (incorrect boolean) so once Johannes fixes that we should be charging:) Assuming all goes well boards and kits will then be in the webshop.

[Jack Bauer]

...and we are charging:)

[Domt177]

Great! Can’t wait to get my board,
Do we know the part numbers of any of the connectors for it?

[JaniK]

Great! Can’t wait to get my board,
Do we know the part numbers of any of the connectors for it?

To me it looks to have the same outside connectors set as Leaf VCU..

[Domt177]

Great! Can’t wait to get my board,
Do we know the part numbers of any of the connectors for it?

To me it looks to have the same outside connectors set as Leaf VCU..

Was more taking for the PCS itself, as I have mine but where do I plug in 12v, 4 HV connections from charging port and main HV DC in/out, and are there buyable connectors for that

[JaniK]

Ah, ofcourse, sorry, for Tesla side I have no idea..

[Jack Bauer]

Boards and kits now available from the webshop and support thread setup :
viewtopic.php?f=10&t=1585

[nkiernan]

Nice one, great work JB (and Irish Elon had a good cameo in the latest video ). Getting my order in now

[P.S.Mangelsdorf]

So to use 12v precharge :

-contactors must report open
-provide hv target voltage from the hvp
-enable dcdc hardware
-ask for precharge
-hvdc reported from the hvp must rise with the precharge voltage
-once target is hit close the contactors and switch dcdc to standby or support function.

Or just use a resistor:)

Yeah regards using the pcs measured hv as the hvp value I'm not sure. Only potential problem I see is the pcs won't start reporting the measured hv via can until its awake. Will test.

Ok, possibly dumb question, but I'm confused. Is precharge necessary for the PCS?

The simplest way for me to wire it up in my car is using only my safety contactor to separate from HV, but that means 12V and HV would turn on at the same time. If it just needs to see 12V first, I can make that happen with only 1 additional contactor, which I think I have on the shelf.

[jokeitch]

Incoming dumb question that I didn't think would be appropriate for the support thread;

Could this setup play nice with the aem vcu200? They like certain on board chargers but I wonder if the expected can IDs for specific values from the obc can be changed, so it's getting the same message.

Not sure if I'd need to mess with the PCs controller firmware to change those IDs around though?

[mixpol]

Hello everyone

I have a faulty Tesla MODEL-3 charger. It does not charge with full power from the 3-phase network.

I would like to run it using the Damien Maguire module.
I made a board according to the scheme on
the STM32F103 processor.

After starting and connecting the CAN monitor, my charger sends data on
different addresses.

Can anyone help me in software adaptation for this version of the charger?

[mixpol]

Where can I download the ESP8266 firmware if available?