MLBevo Charger- 11kw & 22kw Info

[Mitchy]

All.

To prevent some confusion, I'm going to split the discussion of VW HV Chargers.
My main work thus far involves the E-Tron Charger, It's fair to say that there's a generational difference between the 1-2 phase PHEV chargers, and the newer MLBevo type used on the Audi E-Tron, E-Tron GT & Porsche Taycan.

The details highlighted below may port over to the ID3/4 type chargers, but I'm unsure yet...

I'll copy over some details posted in the other charger thread, eventually the data here will be integrated into the WIKI once a proof of concept is proven.

1. CAN Messages
2. Connector Info
3. Coding Options (VCDS/PIWIS/ODIS)
4. Proof of Concept test
5. Base wiring required

This very much is a group effort, with Damien proving the chargers are workable, and a few others helping along the way. This thread is mostly just to compile the info.

[Mitchy]

CAN Messages
CAN signals likely required - Thus far these are the signals I've decided to send for the proof of concept.
We'll likely trim these back once we know what is critical and what is just for aux functions

Required:

• BMS_01 - 0x191

• BMS_02 - 0x1A1

• BMS_03 - 0x39D

• BMS_04 - 0x5A2

• BMS_06 - 0x59E

• BMS_07 - 0x5CA

• BMS_09 - 0x96A955EB

• BMS_10 - 0x509

• BMS_11 - 0x96A954A6

• BMS_16 - 0x9A555539 - Just contains IDs for cells with low/high charge or temps

• BMS_27 - 0x9A555552

• BMS_DC_01 - 0x578 - Contains the HV DC Voltage for CCS

• ESP_15 - 0x1A2 - Holding Management System info

• Klemmen_Status_01 - 0x3C0 - Key status Run/Start, etc...

• DCDC_01 - 0x2AE - 12V DC converter - Just values related to electrical load

• HVK_01 - 0x503 - Items related to HV Contactor & JB

• HVEM_02 - 0x5AC - Useable Energy for Comfort Functions

• HVEM_05 - 0x552 - Fun items relating to Max Voltage and Plug Release

Signals I'm sending In addition:

• Airbag_01 - 0x40 - Monitors HV Deactivate status

• BCM1_04 - 0x64F - BCM Charge Status indication - Likely just confirmation feedback

• DCDC_03 - 0x5CD - 400v to 800v converter - Likely not required

• EM1_HYB_11 - 0x37C - Signal for E-Motor Status - Can be 0 for standby

• FCU_02 - 0x17B - Contains Tank Flap Release & Signal which may go High to signal ready for charging (EPB, Drive System Disabled)

• NavData_02 - 0x485- This along with Authentic_Time_01 contain a 32-bit epoch unix time, used for the charge time calculation.

• VIN_01 - 0x6B4 - Mux'd VIN# - Likely not required or just mimic the Donor Vin?

• ZV_01 - 0x184 - Signal to unlock via ZT - Maybe will unlock charge plug

• ZV_02 - 0x583 - Lock status, likely not required

Signals I haven't added:

• Dimmung_01 - 0x5F0

• Einheiten_01 - 0x643

• ESP_49 - 0x96A954AE - Contains Value for Regen reserve, Guessing that ESP will average typical SOC% to reserve to allow regen - Likely not required

• NVEM_02 - 0x663 - Contains Battery Voltage from Battery Data Module

• MSG_HYB_30 - 0x153 - Only seems to use the Counter & Checksum?

[Mitchy]

Connector Info

[Mitchy]

Coding Options (VCDS/PIWIS/ODIS)

The MLBevo chargers seem to all use the EV_OBC3Phase1KLOMLBev16B config/odx
I primarily use Porsche PIWIS tools, and since the Taycan uses a similar charger, the engineering and coding options match up.
Other similar tools that can be found are VCDS, iDex, ODIS Engineering & OBDEleven... All should allow modifying the charger coding.

I've created a VCDS Label file to aid in coding, It's attached.
You can open in the VCDS LCode.exe program (no purchase needed) and it's a interactive way to determine the coding value required.

The coding breakdown is listed below:

Bitfield 0 -
CP standard - SAE/
vehicle category - Electric Vehicle / Hybrid
20kW charger
AC charging socket B
AC charging socket A
PLC charging socket B
PLC charging socket A
DC Charging - Chademo
Bitfield 1 -
Country encoding (NAR/
HV activation auxiliary contactor
Charging socket resistor B
Charging socket resistor A
AWC installed - Wireless charging
Number of AC chargers (One/Two)
Bitfield 2 -
Mobile Online Services (MOD)
Sub-Grid operation
Charging cover lock (charging socket B)
Charging cover lock (charging socket A)
HV activation DC charging read back
Maximum charging current (63A)
Bitfield 3 -
Charging cover lock detection (charging socket B)
Charging cover lock detection (charging socket A)
Plug lock DC charging socket
iWWT - Integrated water heat exchanger?
Type of connector lock detection - Limit Switch
Plug lock (charging socket A)
Brand/Marque (VW/Audi/Porsche)
Bitfield 4 -
Plug and Charge (PnC)
Power Line Communication
Settings Clear error memory
HV charge booster (400v->800v)
Charging button module
Second charging button
Local HV interlock
stimulus line installed
Bitfield 5 -
Variant coding 11 kW (reserve)
Parking Heater
Kessy
Diagnostic resistor loading button
LED 4 (DC/Combo)
LEDs DC/Combo
LED 4 (AC)
Bitfield 6 -
DC China socket installed
Installed DC combo box
Intelligent charging socket installed (LIN socket)
Installation status of DC charging socket B
Installation status of DC charging socket A
Two charger can B
Charging button module socket B
Diagnosis resistance charging button socket B
Bitfield 7 -
Installation location DC charging socket

The VCDS Scan for my charger is as follows:

My LCode Lable File looks like this:

You can download LCode from Here:
https://forums.ross-tech.com/index.php? ... 117/page-7

Coding label is uploaded as a TXT file, Rename to .xpl or .lbl to open

[Mitchy]

Proof of Concept test

The proof of concept was successful
Managed to convince the charger to spring to life

I'll have to cleanup my Arduino sketch, and pass it along for the community to replicate
My sim setup has a Teensy 4.1
The base sketch I used was Damien's PHEV code, modified for the flexcan_t4 and teensy in general.

Sequence of operation:

The charger has some base requirements for CAN messages. Seems they're requiring more of the signals

**Will add more**

[Mitchy]

Base wiring required

I've started to combine several wiring diagrams along with info gathered by Damien.

As it looks, the modules have a standardized IO layout, with only several differences pending the configured settings.

The info posted below is theoretical for now, until I get to test most of them:

Confirmed the following:
Pin 1 - 12V DC+
Pin 3 - Sensor Ground (Both pin 3 and 45 can be tied together)
Pin 9 - CAN H
Pin 10 - CAN L
Pin 30 - Charge Port - AC+
Pin 33 - Charge Port Cover Position Switch *Other side tied to sensor ground pins 3/45*
Pin 35 - LED Common
Pin 36 - LED Red
Pin 37 - LED Green
Pin 38 - LED Blue
Pin 39 - Socket Illumination LED *Other side tied to ground pin* (Debating if this should be tied to the 3/45 pins)
Pin 40 - Charge Port - CP
Pin 41 - Charge Port - PRX
Pin 45 - Sensor Ground (Both pin 3 and 45 can be tied together)
Pin 46 - Plug Lock +
Pin 47 - Plug Lock -
Pin 48 - Plug Lock Position (Resistive 1k/11k unlocked/locked) *Other side tied to sensor ground pins 3/45*
Pin 49 - Charge Port - DC+
Pin 51 - Charge Button *Other side tied to sensor ground pins 3/45*
Pin 52 - Charge Port - DC -
Pin 60 - Ground

[Mitchy]

*Alternate Coding Options*

VCDS is likely the best option for most, but there are also other tools that friends/family may have.
ODIS Engineering is a common tool that works with some of the simpler dongles.
iDEX is also an option (however I have yet to get it working)
Finally I use PIWIS3 for my coding and a VAS6154 cable It's a bit more user friendly, but requires some additional setup and isn't as common.

Below is my post coding result from ODIS using a VAS6154 cable:

From this you can see that my final coding is:
2A49A04442614A000000

[Mitchy]

Quick test video.
Doesn’t have the typical showmanship of others on here, but wanted to get something out to the community that it’s possible.

[Mitchy]

Some Good News!
After more ODIS messing about, I Managed to copy over the newer project files for the AU58X platform into ODIS Engineering 12.
This at least gets us the same text based mapping as my long coding calculator above...
The project files should be copied into the following folder on the ODIS Engineering Install: C:\ProgramData\Offboard_Diagnostic_Information_System_Engineering\MCD-PROJECTS-Engineering\DSVR-ProdiMCD

Download link for the Project Files, A 7z file of the IDEX Project file folder, Gofile link as it was the easiest way to get this out:
https://gofile.io/d/8jLy7v
Will try to upload to a more suitable host in the future


Below is the explination on how to code via ODIS.
There are also lots of Youtube videos explaining module coding, but I wanted to make this a bit more specific for the charger:

• To Open, Click the blue Icon ODIS - Engineering

• When Opening ODIS, You'll likely get some startup errors, after they timeout, Say OK.

• Select your interface; This will likely be the trickiest part of the whole configuration.

• Select your Project, If you copied the project files over, you'll see AU58X_IDEX in this list

Project Selection.JPG (20.05 KiB) Viewed 5464 times

• After a period of unpacking and preparing, you should be greeted with a list of modules that exist as options, all of these will show a red X, along with the charger.

• Scroll down to C6, Select and navigate to the right to coding, double click. Comms should be established and the program should read the latest coding within the charger.

• With the coding screen loaded, you should see the following options:

Select what options you wish to configure for, when done, the list will be populated with whatever changes were made, and you should be able to click apply to save the settings.

[Mitchy]

LIN Devices still show up within the DTC Memory, However no functional issues with them disconnected as long as the coding has them coded out.
Similar errors exist for the door and other coded out options.
My assumption is that the base software still has the DTC codes enabled for faults, however the selection is universal for the base charger option.
(much like how most times you can code out a O2 sensor, but the DTC code will remain unless digging deeper into the ECU programming)

[evMacGyver]

Very nice work indeed! I'm not familiar with VW parts, do you know the difference between last digits, 5QE915684xx there are many parts with this number. Some have visible difference, cooling port location at least.
Is there any markings on original connectors to identify them?

[Aragorn]

In the VAG world, the last digit(s) could be anything from a minor revision/update to a completely different fitment.

The first three digits are platform code (5QE)
The second three are group and subgroup codes within the parts cataloguing system. 9 is "electrical" for instance, 15 might be "Battery" or "charging"
The last three are the specific part within that subgroup. for instance "the HV battery charger"

The last digit(s) then differentiates versions of that. If there was a single phase and a three phase version for instance, they would have different letters. But similarly if there was a revision or update to that item, it would also get a new letter.

[LRBen]

I have a 7.2kW Cayenne Phev charger which I think belongs to this family as well. Only has the one hybrid canbus and I have it running on Mitchy's script. Model number 5QE 915 681 BQ.

I have narrowed down the required canbus messages to the following:

10ms:
0x191

100ms:
0x3C0
0x503
0x1A1

This is the minimum required to get it to charge. I think it might be missing the socket unlock commands now, but that never worked with this charger anyway.

[LRBen]

I've had a good go at porting this code to the Zombie, but it's proving to be a bit more than my limited coding skills can handle at the moment.

I'll keep trying, but if anyone gets bored of waiting here is the cut down arduino script that runs the charger.

[evMacGyver]

Cable side AC connector is TE YHVA630-5phm-6mm-A and HV output coding A is 2141256-1. But I have no information about data connector so is there any markings for a clue even if its vag own connector? Or any part number for wiring harness that have this connector?

[LRBen]

Cable side AC connector is TE YHVA630-5phm-6mm-A and HV output coding A is 2141256-1. But I have no information about data connector so is there any markings for a clue even if its vag own connector? Or any part number for wiring harness that have this connector?

It's the same as the other VW chargers, VW part number 5Q0906379. Pins are two sizes of TE pins 5-968221-1 and 1241608-6.

[Jacobsmess]

Cable side AC connector is TE YHVA630-5phm-6mm-A

Have you found a cheap source for this, mouser UK wanted over £100 just for the connector!

[jrbe]

Have you found a cheap source for this, mouser UK wanted over £100 just for the connector!

https://octopart.com/search?q=TE+YHVA630-5phm-6mm-A click show all near the bottom left to expand all the resellers.

Might be cheaper through a vag dealer if you have their part #.

[Jacobsmess]

Might be cheaper through a vag dealer if you have their part #.

Thanks, cheapest is through TE direct at £80 or so but they're out of stock.
They do have the STP file on their website though... I wonder if it would be possible to 3d print something equivalent...

Using the audi part number for the entire loom returns prices of around £400...

[jrbe]

Using the audi part number for the entire loom returns prices of around £400...

It's been a while since I hunted down a specific connector. ETKA had an electrical section with individual connectors that you could buy along with terminals. It was a pain to dig through though.

They do have the STP file on their website though... I wonder if it would be possible to 3d print something equivalent...

JLCPCB does 3D printing too, https://jlc3dp.com/
Verify all the features are there before printing it.

[evMacGyver]

Started to investigate 684J 11kW charger. Used lcode but to code using vcds security code is needed so that was no go. Need to get some odis compatible adapter next, I think.

[LRBen]

Started to investigate 684J 11kW charger. Used lcode but to code using vcds security code is needed so that was no go. Need to get some odis compatible adapter next, I think.

If that's one of the batch from Lars I believe it's probably from a Taycan and probably won't response to ODIS. At least in my experience. Might be best to look for a VAS6154 device and get PIWIS.

[evMacGyver]

If that's one of the batch from Lars I believe it's probably from a Taycan and probably won't response to ODIS. At least in my experience. Might be best to look for a VAS6154 device and get PIWIS.

This one is from Audi e-tron or thats what I was told. I think VAS6154 is good for odis too, so looking for one.

[Mitchy]

Try 20103 for the security code; I thought I documented it above but looking back I may not have.

Mongoose seems the easiest and cheapest ( $30 for a knockoff unit that can do J2534)
VAS6154 adapters seem to run ~$60.

[LRBen]

Finally managed to port the teensy script over to Zombie and had my Cayenne charger working in the vehicle yesterday. Still a few basic bugs to iron out but that shouldn't be too hard.