Model 3 PCS Controller Support Thread

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

Post by Jack Bauer »

New STM32 software testing on bench. Basic functions all working. As you can see I'm having a "slight" problem with some of the temp calculations. Elon decided 11 bit signed ints are the order of the day and the STM32 (or more likely my lack of programming skills) doens't seem to like that. Anyway, work progresses with the aim of a beta release tomorrow.
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Re: Model 3 PCS Controller Support Thread

Post by nkiernan »

Got to give the Beta firmware a run this morning, nice work JB :) Couple of comments. Some of the default values set after firmware upload fall outside the min and max range for now. Look to be missing some of the drop down selection boxes such as 'inputtype' and 'Alertlog' so couldn't activate the error log test yet


First two screenshots when PCS controller powered up but no enable signal. No AC or DC HV connected for either to match my earlier test above. Looking to get the same error messages.
030922_PCS_No_Enable_003.JPG
030922_PCS_No_Enable_004.JPG

Next three screenshots when enable signal connected. On previous firmware with this test, PCS controller opmode changed to 'Run' at this stage, stays 'Off' here?
030922_PCS_No_Enable_005.JPG
030922_PCS_No_Enable_006.JPG
030922_PCS_No_Enable_007.JPG
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Re: Model 3 PCS Controller Support Thread

Post by Jack Bauer »

Ok I have no idea why the parameter database is doing that. Attached is my set so I'd load that in and do a reset and that should put things back to normal. Probably an artifact of me moving params around in the new code. The PCS will only respond to the enable line if in manual mode so I'd guess that's where the problem lies. Try those params and lets see if the interface displays properly.
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Re: Model 3 PCS Controller Support Thread

Post by Jack Bauer »

Will go for an early forum release on the latest video or we'll have a lot of confused folks:)


Found a bug in the input type. Release code updated : https://github.com/damienmaguire/Tesla- ... ses/tag/V1
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Re: Model 3 PCS Controller Support Thread

Post by nkiernan »

Tried the new release and now get three sensible/expected alerts. Uploaded your json file and looks to have fixed the drop down menus too :)

030922_PCS_No_Enable_008.JPG
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Re: Model 3 PCS Controller Support Thread

Post by Jack Bauer »

Just this morning received my second customer PCS for testing with the new controller firmware. At first power up we got a "30CanRationality" alert as this is a US spec single phase 48A model. Made some changes to the firmware to adapt the necessary CAN messages depending on PCS version connected and presto we are up and running. As of now the controller and firmware is tested working on :

1x 3p EU PCS from circa 2020 model year car.(customer sent to me for testing)
1x 1p US PCS from circa 2018 model year car. Running in my E46 touring.
1x 1p US PCS from circa 2020 model year car (customer sent to me for testing)

So as of now until I get some more feedback from customers / users of the firmware this is as much as I can do. Beta release firmware updated now on the repo :
https://github.com/damienmaguire/Tesla- ... ses/tag/V1

If some folks could update the wiki page that would be much appreciated as it is a bit sparse :
https://openinverter.org/wiki/Tesla_Mod ... %22PCS%22)
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Re: Model 3 PCS Controller Support Thread

Post by Jack Bauer »

Spent some quality time today with a rather interesting PCS with what seems to be a very new firmware. Apart from Elon messing about with the CAN he added a bunch of new alerts to 0x3A4. Good news is its now up and running and I'll push a firmware update to the repo in a day or two once testing is out of the way. I'll leave you with one of the new alerts to pop up today ...
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Re: Model 3 PCS Controller Support Thread

Post by Jack Bauer »

@nkiernan could you test the new release on the repo please? should take care of your 23CPmia alert.
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Re: Model 3 PCS Controller Support Thread

Post by nkiernan »

Jack Bauer wrote: Wed Sep 07, 2022 5:23 pm @nkiernan could you test the new release on the repo please? should take care of your 23CPmia alert.
Yes, 23CPmia alert now gone :) In manual mode, I get 4 alerts but the first two are the same 28chargeOutputUv
070922_PCS_002.JPG
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070922_PCS_004.JPG

Couple of drop down menus were missing again after the upload, so loading your jsons again got them back
070922_PCS_001.JPG
Apologies I've not got to try the DC-DC and AC charging yet, plan to try get Zombie HVrequest to do the pre-charge HV connect to the PCS at the weekend and should get to try these
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Re: Model 3 PCS Controller Support Thread

Post by Jack Bauer »

No apology necessary and thanks for the feedback. Sure would be nice to have some others contribute ...
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Re: Model 3 PCS Controller Support Thread

Post by P.S.Mangelsdorf »

Jack Bauer wrote: Thu Sep 08, 2022 7:48 am No apology necessary and thanks for the feedback. Sure would be nice to have some others contribute ...
I'm trying to find somewhere that has the ISO7741 in stock, and deal with sudden work chaos. (damn real world) Anyways, once I have the new isolator in I should be able to get some testing done.
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Re: Model 3 PCS Controller Support Thread

Post by fredd90 »

Hello, long time since i had my pcs connected, Did a quick test and installed the latest firmware. First i tested the dcdc and success then both and also success :D

Attached pictures from computerscreen.

3phase 400v @ 10,6kw I think every needed value is valid.

Amazing work👌🤗🙂
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Re: Model 3 PCS Controller Support Thread

Post by Jack Bauer »

P.S.Mangelsdorf no problem. I have 2 ISO parts here if you cant find any pop me a pm.

@fredd90 brilliant thanks for the test:) any ideas on age of your pcs?
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Re: Model 3 PCS Controller Support Thread

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Jack Bauer wrote: Thu Sep 08, 2022 12:13 pm P.S.Mangelsdorf no problem. I have 2 ISO parts here if you cant find any pop me a pm.

@fredd90 brilliant thanks for the test:) any ideas on age of your pcs?
My battery is from a 2019 Norway Tesla model 3, that's all I got👍
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Re: Model 3 PCS Controller Support Thread

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Got to connect HV to the PCS today and do some more testing. Manual mode and DC-DC option only to start. Applying enable generated a count of 5 alerts, but only three unique alerts. Not quite sure what they mean yet, and likely to do with my setup. Didn't get any DC-DC charging for the 12V battery. My 12V battery voltage was very low after a days messing about and I have a vague memory there's a minimum voltage required...need to check

100922_PCS001.JPG
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Changed over to charge mode and was using a type 2 granny cable. EVSE unit clicked into action and green charge LED flashed away so appeared working. Starting HV was 381.2, finished 381.7 after 10 mins or so, but think the screenshots I captured changed along the way
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Re: Model 3 PCS Controller Support Thread

Post by Jack Bauer »

In this case the Alerts tell the story. First DCDC. As you guessed your battery is too low as per 67dcdcLVrationality.
The charger in your PCS is a 3 phase unit so you have 4 AC mains inputs : N,L1,L2and L3. Its capable of running on single phase, 4 wire 3 phase or 3 wire 3 phase. Assuming you are running from single phase then you need to connect to N and...... not L1:) as that would be too easy. What happened is your PCS saw 230v between N and L1 and set grid config to 3 (3p) phase as you can see from your spot values. The Elon brain then got confused as it didn't see the AC on all 3 phases so gave :52acvoltagenotpresent and 90expectedacvoltagesourcemising. So you need to find the right phase to apply power for single phase operation and then gridConfig will show 1p for single phase and you will then need to ask elon nicely for some power using the pacspnt parameter.

Folks, there is a lot of info being dumped here and questions answered that I just know will pop up again and yet not a single word has been added to the wiki page despite my asking regularly. That's cool. I won't ask again but don't get all worked up in the future when I don't answer the same questions.
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Re: Model 3 PCS Controller Support Thread

Post by nkiernan »

Thank you. So charged the 12V battery with a car charger and went back for some more testing. Cautiously setting some values low as I get familiar with things. Started with the DC-DC.

Set udcdc to 13.5V and apply enable in manual mode. PCS jumps into gear and 13.5V reported in the web interface. After a short time, a high pitched whine starts coming from the PCS (got excited thinking the GS450H inverter finally woke up :D ). The volume of the whine increased over a few seconds then stopped and the PCS shut down the DC-DC. This happened a couple of times and I suspected it might be that the 12V battery was still on the low charge side (alerts: 76dcdcEnDeassertedErr, 67dcdcLvRatuionality, 38claFaulted, 50dcdc12VSupportFaulted). After some restarts I changed udcdc to 14V and the PCS DC-DC worked away happily after that. It did happen once more later on when I was trying to test both DC-DC and Charging at the same time. But happily, DC-DC was working on the bench and I didn't blow anything up!

Moved on to testing the charging. Seems N and L2 sets GridCFG to show the correct 1P for my setup. Charging didn't work for me this morning but I know I need to watch back over the recent PCS videos, this is down to my own timing/settings. Manual, enable on, plugging in the granny charger and refreshing sets GridCFG, shows charge power available and the AC voltage available ok, the green charge light on the EVSE box flashes green for 10 seconds or so, but each time it seemed to fault out and show the red LED. The alerts were carrying over between tests so below is only for reference, I'll do a clean test later to capture the specific alerts

110922_PCS008.JPG
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110922_PCS011.JPG
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Re: Model 3 PCS Controller Support Thread

Post by nkiernan »

Jack Bauer wrote: Sun Sep 11, 2022 8:42 am Folks, there is a lot of info being dumped here and questions answered that I just know will pop up again and yet not a single word has been added to the wiki page despite my asking regularly. That's cool. I won't ask again but don't get all worked up in the future when I don't answer the same questions.
Guilty...I need to spend some time at the wiki with what I've learned, will do this week :)
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Re: Model 3 PCS Controller Support Thread

Post by nkiernan »

Ok, start made on the wiki so if anyone see's error's I've made so far, let me know
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Re: Model 3 PCS Controller Support Thread

Post by paaa »

I noted a few bits when looking at us spec unit over the weekend and took some pics as ac connector layout differs , ill get them put in wiki during the week.
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Re: Model 3 PCS Controller Support Thread

Post by Jack Bauer »

Appreciate the wiki edit thanks. Do keep in mind there is no need for any chicken dancing with enable lines,manual mode,evse etc. Just set inputtype to your evse type and plug in the cable.
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Re: Model 3 PCS Controller Support Thread

Post by Jack Bauer »

New batch of PCS controller boards ordered from JLC this morning. Pleased to say it looks like the chip shortage nonsense is easing up. All smd parts placed:)
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Re: Model 3 PCS Controller Support Thread

Post by nkiernan »

Jack Bauer wrote: Mon Sep 12, 2022 7:56 am Appreciate the wiki edit thanks. Do keep in mind there is no need for any chicken dancing with enable lines,manual mode,evse etc. Just set inputtype to your evse type and plug in the cable.
This was what I was expecting alright, once set up just apply enable and plug in the cable (type 2 granny cable in this case). I tried both with and without applying enable but the web interface shows the PCS stays off in both cases. Now with enable connected, I do get a value for evselim. You will notice the PCS_Type shows 48A_1P. This seems to be after I upload the json parameters posted here previously as a fix for the missing drop down menus. Each time I cycle the power, the menus are missing and I have to upload those params (I should create my own to match my setup). Is anyone else seeing the same missing drop downs? Happens on both laptop and phone for me

120922_PCS005.JPG
120922_PCS006.JPG
120922_PCS008.JPG

In manual mode, things look to be working ok, DC-DC and 1P charge
120922_PCS004.JPG
120922_PCS001.JPG
120922_PCS002.JPG

So for a final test, I changed all parameters to the ideal setup, inputtype: Type2, activate: both, alerts: on. Power cycled the PCS controller and as before the drop downs disappeared. This time I assumed the settings I had before power cycling remained and I didn't upload any parameters file. Applied enable, plugged in the charging cable...I should have saved my parameters file at this stage to be sure what everything was set at (missing drop downs). Looks to be the manual input type after all. I have a suspicion not all parameters are saving when power is turned off and I need to test this
120922_PCS010.JPG
120922_PCS011.JPG
120922_PCS012.JPG
120922_PCS013.JPG
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Re: Model 3 PCS Controller Support Thread

Post by Jack Bauer »

The menu problems would indicate the STM32 memory is corrupted. If you have access to an ST link I would do a chip erase and reflash the bootloader and new firmware. Otherwise a replacement STM32 or complete board would be the best option. I should have a batch of new boards from JLC in about 10 days.
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Re: Model 3 PCS Controller Support Thread

Post by nkiernan »

Got the menu's issue sorted. Uploaded the latest firmware again (a few times until it uploaded without any pauses), still missing menus at this stage, uploaded Damien's parameters file, and saved to flash. After this the menus remain after power cycles.

Also addressed an issue I was having where proximity was not being detected. I wasn't sure the PE pin of the charge port should be connected to 12V ground/chassis ground so I hadn't connected it to anything. Connecting this to ground now gets proximity enable working in the web interface.

Have a question about the operation of the PCS/controller between charging and driving modes. In my case 'inputtype = Type 2', 'activate = Both'. My understanding is for charging, apply 12V enable to PCS input 1:enable pin, plug in Type 2 charger cable, and DC-DC and charging will start up. Seems to work as expected.

For normal driving mode, I would expect applying 12V enable to PCS input1:enable pin would start the DC-DC, but this doesn't seem to be the case. What is the correct way to get DC-DC on its own? (other than manual mode)
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