openinverter forum

Have another question about one of the error codes also. Looks like I keep getting error: 38claFaulted but I can't seem to find an explanation of what this error is?

I suspect this is to do with the 12V side and possibly to do with a poor quality 12V battery. When I connect the charge cable, DC-DC starts up and the web interface reports system is putting out the required 14V. After a short period, a high pitched whine starts at low volume and gradually increases over a period of 5 to 10 seconds, before stopping...a few low volume clicks, quiet, and then the cycle starts over again. Refreshing the web interface during this shows the DC-DC shuts off, and restarts. This seems to be coming from the small PCB behind the 12V terminal block from the PCS (as in the pics below)

These Olimex wifi modules seem to be getting worse. I am working on that in parallel. Regards activating the DCDC in drive....ooops! Genius here forgot about that one:) Leave it with me a few days. I'm not up on every fault in the pcs but claFaulted is indeed generated by the DCDC so a different 12v battery would be my first port of call. What do your DCDC temperatures look like?

Jack Bauer wrote: ↑Tue Sep 20, 2022 8:37 am What do your DCDC temperatures look like?

Cool, thank you No coolant set up for the testing yet, didn't think they were too high but maybe that could be it:

Is it ever necessary to have different DC-DC voltages for either driving or charging? Eg: 14V while driving when more load on 12V battery, but for hours of charging with lower draw on the battery, <14V is enough?

Those temps are fine. Never needed different voltages myself but it would be easy to add a "DCDC DriveV" param if folks want?

Jack Bauer wrote: ↑Wed Sep 21, 2022 7:39 am Never needed different voltages myself but it would be easy to add a "DCDC DriveV" param if folks want?

I thought it would be a useful option but maybe I'm over complicating it.

As a data point, several auto mfrs with ICE powerplants have the ECM change the alternator's charging characteristics dynamically, such as dropping the charge voltage during heavy acceleration demands, and upping it during braking.

I recall, around 2005, having to fix a no-charge situation on a by-then old Honda (I believe) by replacing the ECM. That was new tech to me, back then. Probably old hat to most, today.

asavage wrote: ↑Fri Sep 23, 2022 1:13 am As a data point, several auto mfrs with ICE powerplants have the ECM change the alternator's charging characteristics dynamically, such as dropping the charge voltage during heavy acceleration demands, and upping it during braking.

I recall, around 2005, having to fix a no-charge situation on a by-then old Honda (I believe) by replacing the ECM. That was new tech to me, back then. Probably old hat to most, today.

Yeah but that's more about load on the engine than electrical load. I don't think we really need to vary the voltage from the DC-DC.

Well, but you could implement higher 12v charge voltage during regen. Just an example of how dynamic DC-DC could be utilized.

nkiernan wrote: ↑Sat Aug 27, 2022 7:43 pm I've not connected pin 2 of the 12 pin connector and I have the V2 also. Poor photo below, I can get a clearer one if needed. All I needed to connect was pin 1 (Gnd/12V-), pin 2 (12V+), and pin 5 (Input 1 connected to 12V+ also) on the 20 way connector, then ground the PCS case. Have a 5A fuse off the battery 12V terminal too. Firmware Damien posted earlier uploaded via the web interface ok, restarted, and could see the error bits info in the web interface.


DSC_8283.JPG

Where did you get this Housing for the PCS Controller Board from EVBMW?

I need one of these

Zapatero wrote: ↑Wed Sep 28, 2022 7:01 am Where did you get this Housing for the PCS Controller Board from EVBMW?

I've had my PCS controller a while so it was before the shortage issue and I was able to get it at Mouser.co.uk I believe

Would you have a part number? That would be awesome! Thanks!

I'm still looking for a 3D printable version of this Plug.
Does this exist? Buying the cable is around 200€ - thats a lot just for a Plug!

Zapatero wrote: ↑Wed Sep 28, 2022 9:17 pm Would you have a part number? That would be awesome! Thanks!

This should be the one, same as used on some of the other controllers such as the GS450H VCU. I have the dual plug version of the PCS controller

https://eu.mouser.com/ProductDetail/Cin ... cycode=GBP

One quick search of this thread with the term "3d print" reveals :
https://github.com/muehlpower/EV-FFB

Can someone please add to the wiki page? I have done so on the first post.

Jack Bauer wrote: ↑Thu Sep 29, 2022 8:45 am One quick search of this thread with the term "3d print" reveals :
https://github.com/muehlpower/EV-FFB

Can someone please add to the wiki page? I have done so on the first post.

Correct, BUT the HV Plug that i posted above is NOT included in this List, so there is no 3D Model of this Plug so far...

Yeah, I looked last night, and meuhlpower's page is mentioned for PCS power connectors in the wiki three times, but he doesn't have any info on that particular connector. I cleaned up a bit of verbiage in that section of the wiki while I was there.

Much appreciated. As usual it will just need someone willing to do the work and publish the results.

I'm going crazy on the task to find the correct housing and plug and pins.
On the EVBMW it says "Enclosure and connectors NOT supplied.Please see attached connector BOM". But where is it attached?
I went through the Wiki and the Thread and the EVBMW website and also GitHub. I ordered the housing from farnell but i just can not find the header. I went through the data sheets but none fits the holes on the board.

I have 35 Pin Holes, must be that one here on the picture

Help appreciated

On Github : https://github.com/damienmaguire/Tesla- ... Pinout.pdf

Perhaps someone could please add to the wiki.

For anyone looking for the Kostal crimp contacts for the high current 12v connector on the PCS these guys have them in stock :
https://www.automotive-connectors.com/c ... 3124734300
Just ordered a few so will report when they arrive.

Release software now updated to use digital input IN2 on the controller as a trigger to activate the DCDC converter during driving. Pull to 12v to activate, release to deactivate. Tested in E39.

https://github.com/damienmaguire/Tesla- ... ses/tag/V1

Jack Bauer wrote: ↑Mon Nov 14, 2022 1:01 pm Release software now updated to use digital input IN2 on the controller as a trigger to activate the DCDC converter during driving. Pull to 12v to activate, release to deactivate. Tested in E39.

Thank you

I'm closing this support thread as it has become too long to be useful. Please describe new issues in a new thread with a descriptive (I NEED HELP is not descriptive!) title. Do not put unrelated issues into existing threads that describe a different topic.