Tesla SDU main contactor not closing  [SOLVED]

Topics concerning the Tesla front and rear drive unit drop-in board
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qmedia2651
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Re: Tesla Charger alternative firmware

Post by qmedia2651 »

My SDU logic board after precharge the main contact will not close precharge is ok . But the main relay not closing. Using sdu drop in logic board V6. Please someone advise can I close the main contact manually with a external switch?
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Re: Tesla SDU main contactor not closing

Post by johu »

Moved this here as it has nothing to do with the charger.

On the topic: is the relay driver given 3.3V? I.e. the left pin IC9 should be 3.3V when the inverter is in run mode. If so, check if the DC switch output (Pin 3 of the main connector) is pulled to ground, i.e. with a small light bulb. If so, check your wiring and relay.
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Re: Tesla SDU main contactor not closing

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Yes I have led set on pin 11 and 3 pin 11 lights up for a few seconds then turns off but led on pin 3 no light.
Please advise 🙏
PS I am using 344 vdc
My udc is 1.59 can't be !?
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Re: Tesla SDU main contactor not closing

Post by johu »

pin 11 will switch off after 5s if udcsw/2 volts have not been reached, i.e. udc < udcsw/2
Something is wrong with your HV wiring/fuse/contactor or, less likely, voltage sense.
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Re: Tesla SDU main contactor not closing

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See pics
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Re: Tesla SDU main contactor not closing

Post by qmedia2651 »

Thank you Johu take care

I have 344DCV at inverter cable's
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Re: Tesla SDU main contactor not closing

Post by Isaac96 »

What value of 'udc' do you see with 344v at the inverter? What value with 0v?
Values of parameters 'udcgain' and 'udcofs'?
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Re: Tesla SDU main contactor not closing

Post by qmedia2651 »

udc = 1.59 with and without 344v
ucdgain = 6.15, dcv =0v
udcofs= 0 , dcv=0
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Re: Tesla SDU main contactor not closing

Post by Isaac96 »

Either a) you don't have voltage at the inverter or b) the voltage sense circuit is borked.
You stated you have 344v at the inverter cables.
So your voltage sense isn't working for some reason.

Check for cold solders on the board? (I don't remember how the SDU voltage sense is set up to be honest).
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Re: Tesla SDU main contactor not closing

Post by johu »

SDU board gets a voltage signal on pin 1 of the 24-pin gate drive connector. Whats the voltage on pin 1 with HV on?
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Re: Tesla SDU main contactor not closing

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Going to pull the inverter out again. will get back ASAP got to get this motor running so i can get it to the shop and start designing the sub frame for my 1991 300CE Mercedes Benz now called
300CEV. I will be using Fusion 360 for frame design
Thanks all for your help take care
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Re: Tesla SDU main contactor not closing

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Found no voltage at pin 1 of 24 pin with 344v on .with pre- charge relay on about 1mv reading
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Re: Tesla SDU main contactor not closing

Post by johu »

That means the bus voltage sense circuit has some fault, maybe a minor one. Unfortunately I don't know how it works, maybe you can find some optical sign of failure.
Or the DC voltage does not quite make it into the inverter.
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Re: Tesla SDU main contactor not closing

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How much current is required to spin this motor ? can it be the battery pack I'm using ? 400vdc infinity Q50 pack but it had 360v they been sitting for 4 months went down to 344v.
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Re: Tesla SDU main contactor not closing

Post by Isaac96 »

Your pack should be fine. If you have DC at inverter then the pack is plenty, the issue is either in the inverter (that voltage sense circuit) or as Johannes said power might not be getting all the way to the inverter. Have you measured voltage at the inverter end of the wiring?
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Re: Tesla SDU main contactor not closing

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Thanks Isaac96 take care looks like another inverter will look for one on Ebay

Here are the pictures of the inside of the inverter input HV
Any thing abnormal?

UDC=1.78V now
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Re: Tesla SDU main contactor not closing

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I see that the SDU HV cables have a small box connected to the + HV cable.
My cable doesn't have that I have my own HV Box and fuse. CAN THAT BE A PROBLEM WITH THE INVERTER.

See picture
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Re: Tesla SDU main contactor not closing

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See picture
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Re: Tesla SDU main contactor not closing

Post by Isaac96 »

No, you don't need that box. Connectors look fine too. Looks like it's the inverter then.
If you have contactors on do you get voltage at the inverter end of the cables?
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Re: Tesla SDU main contactor not closing

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Yes I do 344v

In the pic correction Vd is 230mv not 230.5v.
Input voltage =output voltage = 344vdc
Therfore this proves that the capacitors are changing .

After checking all voltage and continuity of IGBT conn 5
And continuity from pin 1 to R31 to Pin 11 on the STM32

My conclusion is that the 24 pin IBGT conn 5 ,pins are not connecting to the inverter pins.

Need part number for 24 IGBT conn 5 it's not on the bill of materials list.

Any one out there please advise 🙏
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Re: Tesla SDU main contactor not closing

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Looks like my IGBT Connection 5 is bad any one knows the info for this connection model number ect ..........
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Re: Tesla SDU main contactor not closing

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Today I put in a new logic board from JLCPCB supplied with Damien's Gerber file they sent me 5 populated boards.
And found same results as with the former one .
CONCLUSION BAD INVERTER. 👎 WELL SHIT HAPPENS.
LOOKING FOR A SDU INVERTER.

I hope the Gerber files are good.
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Re: Tesla SDU main contactor not closing

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Just got a inverter waiting for its arrival
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Re: Tesla SDU main contactor not closing

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Hopefully this one will be OK
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Re: Tesla SDU main contactor not closing

Post by Peter »

Hi qmedia2651. I am looking for a replacement inverter, could you let me know who may have one please ? Thanks. Peter
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