openinverter forum

Setting up a support thread for the open source Tesla Model 3 PCS controller.
Please only use this thread for questions relating to the PCS controller, for more general discussion of the PCS and its capabilities and controller development see here :
viewtopic.php?f=10&t=171

Wiki: https://openinverter.org/wiki/Tesla_Mod ... %22PCS%22)

This design is open hardware and software. Sources on Github here :
https://github.com/damienmaguire/Tesla- ... ree/master

Software is based on the Openinverter system and features a full wifi / web browser based interface.
Demo video :

Controler kit :https://www.evbmw.com/index.php/evbmw-w ... -3-pcs-con

NOTE : Links will be updated as we get things fleshed out, wiki updated, videos made etc.

The connector used for communications with the PCS :
https://www.te.com/global-en/product-1379662-5.html
https://www.mouser.ie/ProductDetail/TE- ... KwrJA1Y%3D
Pins : https://www.mouser.ie/ProductDetail/TE- ... DUA4Ad4%3D

In true Muskian fashion it seems they use the 1379662-5 natural color variant of the plug which has no coding tabs. It is of course unavailable from mouser. The black and green variants are functionally identical and should work with coding tabs removed.

3d printable plugs for the PCS : https://github.com/muehlpower/EV-FFB

Update : 20/04/21 : attached pinout and connector data document

Update : 01/12/21 : In an effort to assist those using the PCS I have now released fully functional and commented firmware for the original SAM3 Arduino Due based PCS controller :
https://github.com/damienmaguire/Tesla- ... r/Software

Update : 09/22 : New Firmware now available https://github.com/damienmaguire/Tesla- ... ses/tag/V1

I have a question regarding contacts to the control unit box, are these included in the delivery or do I need to buy these separately?

Have searched the forum but did not find an answer to my question, should probably be on Mouser or Tme

Thanks in advance

Plugs are not included. Hold tight a pinout with accompanying part numbers is on the way:)
EDIT : Please see above.

Note : due to a severe restriction on the supply of the Cinch Me-Mx connector header there are two variants of the board. One with the Me-Mx and the other with a 35 way Ampseal header. Both are the same circuit just a different header. Pinouts for the Ampseal variant will be posted here and on the repo shortly. I have also commissioned the design of a 3d printable housing for the Ampseal variant of both this and the Chademo controller. This design will be posted on here and on the repo once completed and test fitted.

I just placed an order for your PCS controller, extemely excited to get this going... A charger suitable for my model 3 modules is the last missing component before I can start testing.

Ken_S wrote: ↑Mon May 10, 2021 7:49 pm I just placed an order for your PCS controller, extemely excited to get this going... A charger suitable for my model 3 modules is the last missing component before I can start testing.

If its an EVSE you're looking for, Ive been running an OpenEVSE on my Gen2 charger. Fun little project build and highly configurable.

Are the connectors for plugging in the 4x HV from charging port, DC to/from HV battery and to charging to 12V battery available online anywhere, as my PCS didn’t come with any.

I'll see if I can find any id markings on mine.

I disassembled my pack myself, so hopefully I can help here. This is the HVDC connector into the PCS.
I think it is either made to spec for Tesla or it is a Tesla made part, none of the numbers turn up anything other than identical salvage parts.

EDIT: Some searching on Digikey turned up these TE contacts that look similar, and based on their drawings would fit. I choke on 14$/pc
https://www.digikey.com/en/products/det ... -2/2327759

Just checked the connectors I have and slight differences. See photos and the stamped codes on the plugs:

Did your connector come from the factory with red and black cables?

Ken_S wrote: ↑Wed May 19, 2021 9:50 pm Did your connector come from the factory with red and black cables?

Yes, came as part of the pack:

There are 3d print options available :
https://github.com/muehlpower/EV-FFB

nkiernan wrote: ↑Thu May 20, 2021 6:50 am

Ken_S wrote: ↑Wed May 19, 2021 9:50 pm Did your connector come from the factory with red and black cables?

Yes, came as part of the pack:

19.gif

18.gif

Very interesting. That looks considerably easier to deal with than the busbars mine came connected to. What year/region/model was your donor, if you know?

Sourced in an Irish EV breakers, an EU 2019 car is all I have on it

Jack Bauer wrote: ↑Mon Apr 19, 2021 8:16 am
Update : 20/04/21 : attached pinout and connector data document

Can you double check the X420 pinout in your PDF? I only ask because I am re-using the harness from my pack, and in the harness connector to X420, there are no wires in the sockets for pins 10,11, or 12, at least according to the pin numbering defined in the connector datasheet. What pin numbering are you using?

That's interesting. So pins 10 and 11 are cp can that is not used by the pcs anyway. Sounds like they deleted them from the loom. Pin 12 is a ground that actually needs to be connected to the case of the pcs so I would also suspect they deleted that in favor of just using the case ground. My pin numbering is as per the service manual wiring diagram. The Wxx numbers are actually printed on the wires so you could check those.

Jack Bauer wrote: ↑Mon May 24, 2021 9:09 am That's interesting. So pins 10 and 11 are cp can that is not used by the pcs anyway. Sounds like they deleted them from the loom. Pin 12 is a ground that actually needs to be connected to the case of the pcs so I would also suspect they deleted that in favor of just using the case ground. My pin numbering is as per the service manual wiring diagram. The Wxx numbers are actually printed on the wires so you could check those.

Thanks for confirming. I wasn't aware the service manual was openly available, I should have googled it a year ago:) Attaching a screenshot here for others to reference. /wrong At a glance it does seem like Tesla isn't using the connector manufacturers suggested pin 1, I will confirm in the morning. /wrong

EDIT: After further review, Tesla does in fact use the manufacturers suggested pin numbering scheme in X420... I incorrecly assumed the connector used a "snake" numbering pattern, which was incorrect. Below is a clip of the connector datasheet with the suggested pin numbering schemed Tesla uses.

Ken_S wrote: ↑Tue May 25, 2021 7:12 am

Jack Bauer wrote: ↑Mon May 24, 2021 9:09 am That's interesting. So pins 10 and 11 are cp can that is not used by the pcs anyway. Sounds like they deleted them from the loom. Pin 12 is a ground that actually needs to be connected to the case of the pcs so I would also suspect they deleted that in favor of just using the case ground. My pin numbering is as per the service manual wiring diagram. The Wxx numbers are actually printed on the wires so you could check those.

Thanks for confirming. I wasn't aware the service manual was openly available, I should have googled it a year ago:) Attaching a screenshot here for others to reference.
Screenshot_20210525-010323~2.png

At a glance it does seem like Tesla isn't using the connector manufacturers suggested pin 1, I will confirm in the morning.

where did you find the service manual?

muehlpower wrote: ↑Tue May 25, 2021 8:12 am

Ken_S wrote: ↑Tue May 25, 2021 7:12 am

Jack Bauer wrote: ↑Mon May 24, 2021 9:09 am That's interesting. So pins 10 and 11 are cp can that is not used by the pcs anyway. Sounds like they deleted them from the loom. Pin 12 is a ground that actually needs to be connected to the case of the pcs so I would also suspect they deleted that in favor of just using the case ground. My pin numbering is as per the service manual wiring diagram. The Wxx numbers are actually printed on the wires so you could check those.

Thanks for confirming. I wasn't aware the service manual was openly available, I should have googled it a year ago:) Attaching a screenshot here for others to reference.
Screenshot_20210525-010323~2.png

At a glance it does seem like Tesla isn't using the connector manufacturers suggested pin 1, I will confirm in the morning.

where did you find the service manual?

I found a manual here, have not bought it myself yet.

https://servicemanuals.online/tesla/140 ... grams.html

Attaching photos of the X420 connector I have for info, last three pins not used on this one either. Just got hold of service manual and wiring diagrams, send a PM

nkiernan wrote: ↑Tue May 25, 2021 9:43 am Attaching photos of the X420 connector I have for info, last three pins not used on this one either. Just got hold of service manual and wiring diagrams, send a PM

22.gif

23.gif

I just went though the wire labels and the connector datasheet again, turns out I was wrong. Tesla is using the manufacturers pin numbering scheme, I just mis-identified the unused positions 7,8,9 as 10,11,12.

I edited my post above with the correct pin numbering scheme, so as to minimize future confusion.

PCS controller up and running and connected to web interface

Until I get a wall charger set up, what would be the minimum requirement to be able to use the PCS with 240V single phase domestic supply to allow some testing and light charging of Tesla pack!? Is a fused connection to the AC charge input allowed? If US versions are 120VAC on two pins, will EU PCS work with similar?

Hello

Now its time to wire up my Pcs controller, is there a chance that you can control the precharge circuit with the pcs controller? I want to have a set of smaller contactors. Maybe use the output pins, is it possible that the parameters are hidden?

Or is it like the other tesla charger, it won't need any precharge circuit? I am asking because original the pcs was connected after main precharged contactors


Did anyone manage to create a 3d-printed shell to pcs controller? =). Otherwise i will let a friend cad and print a test

Got in to problems, I think

Everything wired up according to the pinout supplied at first post.

Can't get any pcs values from Web interface, connecting and logging in went great

I have selected eu version,

Is there any more changes to get things working?

Got 5v at pin one and pcs is mounted in penthouse,
Also got 13v at pin6(pcs-enable) with or without communication cable connected.


Attached a picture of my pcs: