Tesla Charger Support Thread

[xp677]

There was a bug on the old v1 pcb with some missing grounds but that was way back. Current designs are fine in that respect to the best of my knowledge.

That's great, cheers!

[bulletbug]

I'm having PCBway.com produce and assemble a v4 board for a Gen2 charger. I'm getting a question from them regarding oxidation of one of the capacitors when they attempt to assemble.

c30 - 10nF Multilayer Ceramic Capacitor MLCC 50V dc ±10% X8R Dielectric 0805 (2012M)

They have apparently tried to add this part 2 times and have said it has oxidized each time. They are asking me if they can send it without the c30.

Please educate me on this. Is this a typical problem? Is it something I can resolve myself? Advice on how to respond to them is appreciated.

[xp677]

That capacitor is on the Reset-switch input of the SAM microcontroller, it's recommended for "harsh environments". I'd try to mount one myself, but if it's not possible, I'd leave it out.

It might be that the particular capacitor that the chose is having issues, you may have better luck with another brand.

It's advisable to preheat MLCCs prior to installation as they do not respond well to thermal shock.

The NRSTB pin is input only and enables asynchronous reset of the SAM3X/A series when asserted low. The
NRSTB pin integrates a permanent pull-up resistor of about 15 kΩ. This allows connection of a simple push button
on the NRSTB pin as a system-user reset. In all modes, this pin will reset the chip including the Backup region
(RTC, RTT and Supply Controller). It reacts as the Power-on reset. It can be used as an external system reset
source. In harsh environments, it is recommended to add an external capacitor (10 nF) between NRSTB and
VDDBU.

[Jack Bauer]

First batch of prototypes have arrived from JLCPCB. Initial observation is that this is top tier board building. As good as anything I have ever seen in my career and better than anything local who have charged a hell of a lot more.

I'd like to appeal for some calm in relation to the whole JLC build. I won't be responding to anymore "DAMIEN! WHEN ARE YOU RELEASING THE JLC BOM AND PLACEMENT FILES!" type of emails or messages on here or otherwise. The boards will be tested. Errors if found corrected. Webshop and github will then be updated and videos made. The vast majority of people are great and appreciate the effort involved but some seem to think I'm their personal design engineer. Newsflash! I'm not.

Now in relation to the webshop we'll be making a few changes. There will be three tiers of board available to buy :

1) Board direct from JLC as I receive them with listed smt placed, unprogrammed and untested. This will replace the bare boards currently on sale.
2) Board direct from JLC as I receive them with listed smt placed, programmed but untested. This gets around the need for programming the micros.
3) Board with all components both listed smt and non listed smt and through hole placed, programmed and tested.

[Jack Bauer]

In advance of releasing the new boards for sale (with significant price drops) I decided to make 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.

[Jack Bauer]

Kinda bad news on the charger board. I done screwed up. Connected the SWD port to the wrong pins on the micro! Fortunately, a misspent youth of chipping playstations allowed me to connect to the right pins and upload the inverter bootloader and test program. CAN and IO are working but will need to re layout the board to correct this and some other errors. Not disappointed as this was my first go at using the STM32F103C8T6 and also first JLC board. I'll be putting up a new thread soon for software developement on the new board which will be a nice comedy show as I get to grips with C++ and STM32 Only took me a week to get an led blinking and CAN transmission working.

[joromy]

I have a gen 2 tesla charger with ver3 board.
Everything is working great!!

But now I want to do some modification to software, and possibly hardware, to make the EVSE contactor stay on.
The reason for this is that I want the battery heater/cooler stay on even if charging is off. (It can run on AC or DC)

Was thinking to set Input2 high on the charger, when battery climate ECU want to heat/cool, and let the Proximity circuit in the charger board turn on EVSE.

The battery climate ECU is CAN capable, but i guess there will be no CAN support on the ver3 board?
Maybe it's time to upgrade to ver. 5 board......

And one more thing, will the charger be OK with AC on all time?

Any input and suggestions are very welcome!!

[Bratitude]

I have a gen 2 tesla charger with ver3 board.
Everything is working great!!

But now I want to do some modification to software, and possibly hardware, to make the EVSE contactor stay on.
The reason for this is that I want the battery heater/cooler stay on even if charging is off. (It can run on AC or DC)

Was thinking to set Input2 high on the charger, when battery climate ECU want to heat/cool, and let the Proximity circuit in the charger board turn on EVSE.

The battery climate ECU is CAN capable, but i guess there will be no CAN support on the ver3 board?
Maybe it's time to upgrade to ver. 5 board......

And one more thing, will the charger be OK with AC on all time?

Any input and suggestions are very welcome!!

What kinda battery? Is this the stock battery heater? If the heater is essentially can controlled then use the spare can bus on the board you have, I’m assuming your not running a master/ space setup.

My understanding is we are loosing a can bus on v5 so you’d have to play some tricks or have a external board to drive it.

Charger can be plugged in all time, running is a different matter. As long as it has adequate cooling then should be alright.


Is it just really cold where you are?

[joromy]

It's a DIY: viewtopic.php?f=16&t=221
With tesla battery.
If i can use the CAN on the charger, would be perfect, but I don't think that is possible.
I know Tom91 have tried to get Simp BMS to control the charger via CAN.

Sometimes It's below 0C outside, but this winter it's been +8C to +10C, "thank you" global warming!!!

[Jack Bauer]

New V5 design based on the STM32F103C8T6 now released on Github. Note that as of today no firmware is developed. Anyone want to lend a hand and get some free boards?

[Bratitude]

For those who are not using the HVJB with their charger, the 6 pin hv molex connector is part number 444413006

You’ll need two

https://www.molex.com/molex/products/da ... USINGS.xml

[bulletbug]

Tesla Gen 2 connectors shown below - I can't track down any mention of these for brand/part number. Can anyone name these beasts?

[Kevin Sharpe]

Tesla Gen 2 connectors shown below - I can't track down any mention of these for brand/part number. Can anyone name these beasts?

Damien's GitHub has the details in a file named 'connectors';

https://github.com/damienmaguire/Tesla- ... ectors.pdf

[bulletbug]

Thank you.

[Bratitude]

The pins for the HV connectors are
Part number 0433750001

Here’s the data connectors too
12pin is : 0194180038
10pin is : 0194180024
You’ll need one of each per charger

Pins: 0194200002

[joromy]

CAN and IO are working but will need to re layout the board to correct this and some other errors.

The protection diode (pin 9 on the ULN chip) should go directly to 12V, not trough D6.
And it should be on 12V all time (not ign. 12V) or you will get some stray current, that could energize low side relays/contactors.

[mane]

My gen3 charger shows feedback from only phase 1 and 2. Phase 3 values are 0. I have checked the wires multiple times, and they are properly connected. Checked them from pins of controller to pins on the charger board. Led lights up when I enable phase 3. So I guess the it works, but CAN does not.

Here's the feedback I get:

2410983 State: 1 Phases : 0 Modules Avtive : 3 ON D1 H
Phase 1 Feebback // AC present: 0 AC volt: 1 AC cur: 0.20 DC volt: 1 DC cur: 0.04 Inlet Targ: 216 Temp Lim Cur: 23 21 25 EN:0 Flt:1 Stat:100001
Phase 2 Feebback // AC present: 0 AC volt: 1 AC cur: 0.20 DC volt: 1 DC cur: 0.06 Inlet Targ: 216 Temp Lim Cur: 23 21 25 EN:0 Flt:1 Stat:100001
Phase 3 Feebback // AC present: 0 AC volt: 0 AC cur: 0.00 DC volt: 0 DC cur: 0.00 Inlet Targ: 0 Temp Lim Cur: 0 0 0 EN:0 Flt:0 Stat:0

I have also checked that the connector legs that used to be connected to board in front don't short. Is there any other place where I could get the CAN high and CAN low for this phase?

Also, would the charger work without having feedback from phase 3?

[Jack Bauer]

I would check if you have can polarity swapped on phase 3. Also measure the bus resistance and check it is 60 ohms.

[Chad B]

I currently have a 12kw Gen 3 in operation, can I add a second 18kw Gen 3 charger using one Gen 3 charge controller? Or do I need another controller for the second Charger?

[Mikedwms]

I have just gotten my Gen 3 charger running. I'm wondering what would happen if I had insufficient cooling? Would I burn up my charger or would the controller shut down the power?

[Jack Bauer]

Most likely it would overheat and explode. Tesla are not Toyota. There is little or no protection built in.

[tom91]

Most likely it would overheat and explode. Tesla are not Toyota. There is little or no protection built in.

Gen 2 charger modules self limit based on temperature. You can clearly detect the pulsing when it is getting hot the draw starts to ramp up and then shut down and ramp up again.

[Kevin Sharpe]

Most likely it would overheat and explode. Tesla are not Toyota. There is little or no protection built in.

Gen 2 charger modules self limit based on temperature. You can clearly detect the pulsing when it is getting hot the draw starts to ramp up and then shut down and ramp up again.

The OP mentioned Gen 3. Do you know the behaviour is the same?

[tom91]

Most likely it would overheat and explode. Tesla are not Toyota. There is little or no protection built in.

Gen 2 charger modules self limit based on temperature. You can clearly detect the pulsing when it is getting hot the draw starts to ramp up and then shut down and ramp up again.

The OP mentioned Gen 3. Do you know the behaviour is the same?

I do not have access to a Gen 3. Surely during development one ran without cooling and this behaviour would have been identified.

If the can messages from the bricks are identical then yes it will work the same way as the bricks report derates and reasons.

[Mikedwms]

Thanks for all your responses. I am planning running a test by throttling back my Cooling water and watching it closely. I will post results soon.