Tesla Large Drive Unit Support Thread

Topics concerning the Tesla front and rear drive unit drop-in board
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Re: Tesla Large Drive Unit Support Thread

Post by P.S.Mangelsdorf »

Have you tried to start up again since? Can you get any movement? Try clearing errors and starting up again.

Also, check your encoder settings. When I had mine set to single mode (instead of AB) I had a similar thing happen all of the time, where it would lose encoder starting off from a traffic light, buck, and die. Once I had pushed it out of the way and unplugged and replugged the encoder, I could get it to work again. The long term solution for me was setting the encoder properly, and that led me to discover that I needed to swap the encoder signal wires (the classic Tesla changing the wiring harness problem).
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Re: Tesla Large Drive Unit Support Thread

Post by P.S.Mangelsdorf »

Also, the newer firmware with Jon's changes gets rid of the slow speed overcurrent issues.
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Re: Tesla Large Drive Unit Support Thread

Post by Boxster EV »

canadasconvert wrote: Sun Jun 19, 2022 10:21 pm I am still having problems with the Inverter/Motor. Since my last post, I have made a few short trips around the bloc and everything was running well until the last trip. I had stopped at a stop sign and was slowly accelerating when the car bucked a couple of times and then no power. I had it towed home and am investigating what happened. I still have 348V of power and the Ign, Pre and Main Contactors are all working. The DC/DC converter is charging the battery so I have 13V at all times. UDC reads 1.48V with and without HV power. I also get the following errors:
[1]: WARN - PWMSTUCK
[65]: DERATE - CURRENT LIMIT
Take the orange HV cover off and check that you’re getting HV to the inverter busbars. Be careful.
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Re: Tesla Large Drive Unit Support Thread

Post by eGrandpa »

I have a Tesla Sport motor in a test-bench setup. I'm using an e-motorcycle hall effect throttle for now. My software version is 5.13R-SINE. I set it up a few months ago using four 12v lead acid batteries in series for approximately 48v plus a separate 12v battery to drive the relays and controller. All worked fine. I just switched the lead acid batteries with three Tesla Model S battery modules in series for approximately 72v. Again, the system runs great with more speed than earlier. The only problem is if I give it very rapid throttle the main contactor opens and cuts power to the motor. Turning the throttle slowly -- it works fine. Per directions, I set UDCSW and UDCLIM to zero. No other changes. Any suggestions?
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Re: Tesla Large Drive Unit Support Thread

Post by johu »

hello electric grandpa :) I don't think you set udclim to 0 because then it wouldn't start, rather "udcmin", right?
Opening the main contactor is the result of a detected over current. This should be less pronounced when the motor is inside a vehicle and can't just spin up freely. Raising ocurlim will move the trip point up but I don't recommend it at this stage. Tesla hardware is kind of brittle.
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Re: Tesla Large Drive Unit Support Thread

Post by eGrandpa »

Yes. You are correct. I typed the wrong parameter. Sounds like it is indeed working fine. I am running coolant through the motor and controller during the test. Thanks for the help.

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Re: Tesla Large Drive Unit Support Thread

Post by canadasconvert »

Further Update to CURRENT LIMIT issue. I pulled the motor and the Inverter cover and saw no issues. IGBT's look good - no bubbles. The two green & one red LEDs on the Inverter Board came on and there were no lights on any of the 3 inverter phases. The Ign., Pre-Charge and Main contactors closed as they should and I was showing full 348V on UDC. I was still getting the CURRENT LIMIT & PWM STUCK errors. I put it into FWD and it spun up at very low speed. DC Voltages on the individual Inverter Phases were A-342V, B-338V, C-344V.
P.S.Mangelsdorf - the Encoder settings are A/B and I swapped the two wires going to the Encoder at the beginning of the build.
Boxster EV - With the meter on AC, I tried measuring AC voltage between the three phases under the Orange cap but got zero. If there was a short, the motor shouldn't spin up. Am I wrong?
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Re: Tesla Large Drive Unit Support Thread

Post by P.S.Mangelsdorf »

When you spun up at a low speed, did it have an error and fail/shut down, or are you just seeing the error messages?
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Re: Tesla Large Drive Unit Support Thread

Post by canadasconvert »

Just seeing the error message. I wasn't sure how to clear errors/faults. I'm just looking that up now.
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Re: Tesla Large Drive Unit Support Thread

Post by P.S.Mangelsdorf »

canadasconvert wrote: Thu Jun 23, 2022 6:42 pm Just seeing the error message. I wasn't sure how to clear errors/faults. I'm just looking that up now.
In the web interface there is a button to clear error history or clear error messages. I don't remember the exact phrasing.

Based on all that you've said, I think that once you clear the messages you should be ok. The failure during low acceleration starts is a known issue solved in later firmware (Jon Volk's solution, discussed here: https://openinverter.org/forum/viewtopi ... 572#p16572 that was incorporated into the full firmware). I'd recommend updating sooner rather than later. I kept putting it off but its truly an improvement.

If your errors persist, there may be some other issue at play.
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Re: Tesla Large Drive Unit Support Thread

Post by Boxster EV »

Boxster EV wrote: Tue Jun 21, 2022 6:28 am
canadasconvert wrote: Sun Jun 19, 2022 10:21 pm I am still having problems with the Inverter/Motor. Since my last post, I have made a few short trips around the bloc and everything was running well until the last trip. I had stopped at a stop sign and was slowly accelerating when the car bucked a couple of times and then no power. I had it towed home and am investigating what happened. I still have 348V of power and the Ign, Pre and Main Contactors are all working. The DC/DC converter is charging the battery so I have 13V at all times. UDC reads 1.48V with and without HV power. I also get the following errors:
[1]: WARN - PWMSTUCK
[65]: DERATE - CURRENT LIMIT
Take the orange HV cover off and check that you’re getting HV to the inverter busbars. Be careful.
canadasconvert wrote: Thu Jun 23, 2022 5:57 pm
Boxster EV - With the meter on AC, I tried measuring AC voltage between the three phases under the Orange cap but got zero. If there was a short, the motor shouldn't spin up. Am I wrong?
I was referring to the DC busbars.
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Re: Tesla Large Drive Unit Support Thread

Post by EV_Builder »

If you do the update of the firmware make sure HV is switched off fully. This especially applies to external controlled HV relais.
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Re: Tesla Large Drive Unit Support Thread

Post by nilsvr »

Hi,

I have a LDU Sport and an openinverter board. Today I wired everything up and immidiatly got an overcurrent error after applying 12V on "start".
Am I doing something wrong or is one of the powersections already blown?

I checked all my contactors without HV before and they opened and closed as they are supposed to when powering up. With no HV after "start" the main contactor stays open (like it is supposed to) but if I check the error messages there is an overcurrent error.

Me not noticing the OC error during testing without HV (because everything seemed to work) led to a testrun with 96V. Precharge worked flawlessly but on "start" the OC error stopped the Inverter and opened the main contactor immidiatly after closing it.

The motor never spun nor made any noise.

I tried changing the sign of ocurlim without any success.

How do I test for a faulty powersection?
On powerup 6 red leds (2 on each of the three boards on the side of the inverter) flash for a moment and then turn off again. Same happens on power off. The openinverterboard has a static red led on the wifi module, a static red led on the board and one constantly blinking red led next to the static one.

I would highly appreciate any help and suggestions.
Best regards
Nils
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Re: Tesla Large Drive Unit Support Thread

Post by jon volk »

What firmware version and parameters?
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Re: Tesla Large Drive Unit Support Thread

Post by nilsvr »

Firmware version 5.13.R-sine
Parameters

{
"boost": 1850,
"fweak": 258,
"fweakstrt": 400,
"fconst": 450,
"udcnom": 390,
"fslipmin": 0.84,
"fslipmax": 3.06,
"fslipconstmax": 9,
"sincosofs": 2048,
"fmax": 540,
"dirchrpm": 100,
"dirmode": 1,
"ocurlim": 900,
"udcgain": 7.43,
"potmin": 895,
"potmax": 4095,
"pot2min": 4095,
"pot2max": 4095,
"potmode": 0,
"throtramp": 5.84,
"throtramprpm": 20000,
"ampmin": 0.34,
"slipstart": 55,
"brknompedal": -55,
"regenramp": 3,
"brknom": 30,
"brkmax": -55,
"brkcruise": -30,
"brkrampstr": 40,
"brkout": -10,
"bmslimhigh": 100,
"bmslimlow": -20,
"udcmin": 0,
"udcmax": 426,
"idcmax": 5000,
"idcmin": -5000,
"idckp": 2,
"idcflt": 9,
"tmphsmax": 85,
"tmpmmax": 300,
"throtmax": 100,
"throtmin": -100,
"iacmax": 5000,
"ifltrise": 10,
"ifltfall": 0,
"chargemode": 0,
"chargecur": 0,
"chargekp": 80,
"chargeki": 10,
"chargeflt": 8,
"chargepwmin": 0,
"chargepwmax": 90,
"idlespeed": 250,
"idlethrotlim": 50,
"idlemode": 3,
"speedkp": 0.09,
"speedflt": 5,
"cruisemode": 0,
"udcsw": 0,
"udcswbuck": 540,
"tripmode": 0,
"bootprec": 0,
"pwmfunc": 0,
"pwmgain": 100,
"pwmofs": 0,
"canspeed": 1,
"canperiod": 0,
"nodeid": 1,
"fslipspnt": 0,
"ampnom": 0
}



Btw your E30 build is my inspiration for all of this I have an E30 316i touring in the driveway
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Re: Tesla Large Drive Unit Support Thread

Post by jon volk »

Thanks!
First thing to try is set udcnom to zero. It’s causing your boost and fweak to change dramatically in the background at only 96v. Good to disable while testing at lower voltage.
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Re: Tesla Large Drive Unit Support Thread

Post by nilsvr »

Changed udcnom to 0 and tried it with no HV and still get the OC error as soon as i apply 12V on start
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Re: Tesla Large Drive Unit Support Thread

Post by jon volk »

The other thing that I’ve seen cause issues is related to idle mode. Try setting idle speed to -100 to disable that as well. If no additional lights come on the gate driver boards during the OC, that’s generally more positive than not that it’s something simple
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Re: Tesla Large Drive Unit Support Thread

Post by nilsvr »

Still no change in behavior after setting idlespeed to -100.
What does idlemode mean? It is currently set to off. I expected this to turn on and off the idle regardless of the idlespeed setting.
I hope its an easy fix i am not keen on buying another DU…
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Re: Tesla Large Drive Unit Support Thread

Post by nilsvr »

Eventhough i have nothing connected to the HV terminals I have a udc of roughly 1,5V and IL1 and IL2 are jumping up and down -4 to 2. Is that normal?
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Re: Tesla Large Drive Unit Support Thread

Post by johu »

nilsvr wrote: Sat Jul 02, 2022 2:36 pm Eventhough i have nothing connected to the HV terminals I have a udc of roughly 1,5V and IL1 and IL2 are jumping up and down -4 to 2. Is that normal?
Yes that is normal jitter.
With idlemode=Off idlespeed does indeed not matter.

Can you post the output off 192.168.4.1/cmd?cmd=json%20hidden

That has also hidden parameters
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Re: Tesla Large Drive Unit Support Thread

Post by nilsvr »

If I type 192.168.4.1/cmd in the searchbar it outputs „BAD ARGS“. Am I doing that correctly? What am i suppsed to do with the „cmd=json%20hidden“ ?
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Re: Tesla Large Drive Unit Support Thread

Post by nilsvr »

Of course you have to type it in one phrase my browser cut it in half after the ?.

This is before the attempt of starting (so no oc error yet). Do you need the output after the error as well?



{
"boost": {"unit":"dig","value":1850.00,"isparam":true,"minimum":0.00,"maximum":37813.00,"default":1700.00,"category":"Motor","i":0},
"fweak": {"unit":"Hz","value":258.00,"isparam":true,"minimum":0.00,"maximum":1000.00,"default":90.00,"category":"Motor","i":1},
"fweakstrt": {"unit":"Hz","value":400.00,"isparam":true,"minimum":0.00,"maximum":1000.00,"default":400.00,"category":"Motor","i":2},
"fconst": {"unit":"Hz","value":450.00,"isparam":true,"minimum":0.00,"maximum":1000.00,"default":180.00,"category":"Motor","i":3},
"udcnom": {"unit":"V","value":0.00,"isparam":true,"minimum":0.00,"maximum":1000.00,"default":0.00,"category":"Motor","i":4},
"fslipmin": {"unit":"Hz","value":0.84,"isparam":true,"minimum":0.28,"maximum":10.00,"default":1.00,"category":"Motor","i":5},
"fslipmax": {"unit":"Hz","value":3.06,"isparam":true,"minimum":0.28,"maximum":10.00,"default":3.00,"category":"Motor","i":6},
"fslipconstmax": {"unit":"Hz","value":9.00,"isparam":true,"minimum":0.00,"maximum":10.00,"default":5.00,"category":"Motor","i":7},
"polepairs": {"unit":"","value":2.00,"isparam":true,"minimum":1.00,"maximum":16.00,"default":2.00,"category":"Motor","i":8},
"respolepairs": {"unit":"","value":1.00,"isparam":true,"minimum":1.00,"maximum":16.00,"default":1.00,"category":"Motor","i":9},
"sincosofs": {"unit":"dig","value":2048.00,"isparam":true,"minimum":1.00,"maximum":4096.00,"default":2048.00,"category":"Motor","i":10},
"encmode": {"unit":"0=Single, 1=AB, 2=ABZ, 3=SPI, 4=Resolver, 5=SinCos","value":1.00,"isparam":true,"minimum":0.00,"maximum":5.00,"default":0.00,"category":"Motor","i":11},
"fmax": {"unit":"Hz","value":540.00,"isparam":true,"minimum":21.00,"maximum":1000.00,"default":200.00,"category":"Motor","i":12},
"numimp": {"unit":"ppr","value":36.00,"isparam":true,"minimum":8.00,"maximum":8192.00,"default":60.00,"category":"Motor","i":13},
"dirchrpm": {"unit":"rpm","value":100.00,"isparam":true,"minimum":0.00,"maximum":20000.00,"default":100.00,"category":"Motor","i":14},
"dirmode": {"unit":"0=Button, 1=Switch, 2=ButtonReversed, 3=SwitchReversed, 4=DefaultForward","value":1.00,"isparam":true,"minimum":0.00,"maximum":4.00,"default":1.00,"category":"Motor","i":15},
"snsm": {"unit":"12=KTY83-110, 13=KTY84-130, 14=Leaf, 15=KTY81-110, 16=Toyota, 21=OutlanderFront, 22=EpcosB57861-S","value":12.00,"isparam":true,"minimum":12.00,"maximum":22.00,"default":12.00,"category":"Motor","i":16},
"pwmfrq": {"unit":"0=17.6kHz, 1=8.8kHz, 2=4.4KHz","value":1.00,"isparam":true,"minimum":0.00,"maximum":2.00,"default":1.00,"category":"Inverter","i":17},
"pwmpol": {"unit":"0=ActHigh, 1=ActLow","value":0.00,"isparam":true,"minimum":0.00,"maximum":1.00,"default":0.00,"category":"Inverter","i":18},
"deadtime": {"unit":"dig","value":63.00,"isparam":true,"minimum":0.00,"maximum":255.00,"default":63.00,"category":"Inverter","i":19},
"ocurlim": {"unit":"A","value":900.00,"isparam":true,"minimum":-65536.00,"maximum":65536.00,"default":100.00,"category":"Inverter","i":20},
"il1gain": {"unit":"dig/A","value":1.00,"isparam":true,"minimum":-100.00,"maximum":100.00,"default":4.68,"category":"Inverter","i":21},
"il2gain": {"unit":"dig/A","value":1.00,"isparam":true,"minimum":-100.00,"maximum":100.00,"default":4.68,"category":"Inverter","i":22},
"udcgain": {"unit":"dig/V","value":7.43,"isparam":true,"minimum":0.00,"maximum":4095.00,"default":6.15,"category":"Inverter","i":23},
"udcofs": {"unit":"dig","value":0.00,"isparam":true,"minimum":0.00,"maximum":4095.00,"default":0.00,"category":"Inverter","i":24},
"udclim": {"unit":"V","value":540.00,"isparam":true,"minimum":0.00,"maximum":1000.00,"default":540.00,"category":"Inverter","i":25},
"snshs": {"unit":"0=JCurve, 1=Semikron, 2=MBB600, 3=KTY81, 4=PT1000, 5=NTCK45_2k2, 6=Leaf, 7=BMW-i3","value":0.00,"isparam":true,"minimum":0.00,"maximum":7.00,"default":0.00,"category":"Inverter","i":26},
"potmin": {"unit":"dig","value":895.00,"isparam":true,"minimum":0.00,"maximum":4095.00,"default":0.00,"category":"Throttle","i":27},
"potmax": {"unit":"dig","value":4095.00,"isparam":true,"minimum":0.00,"maximum":4095.00,"default":4095.00,"category":"Throttle","i":28},
"pot2min": {"unit":"dig","value":4095.00,"isparam":true,"minimum":0.00,"maximum":4095.00,"default":4095.00,"category":"Throttle","i":29},
"pot2max": {"unit":"dig","value":4095.00,"isparam":true,"minimum":0.00,"maximum":4095.00,"default":4095.00,"category":"Throttle","i":30},
"potmode": {"unit":"0=SingleRegen, 1=DualChannel, 2=CAN, 3=CANDual","value":0.00,"isparam":true,"minimum":0.00,"maximum":3.00,"default":0.00,"category":"Throttle","i":31},
"throtramp": {"unit":"%/10ms","value":5.84,"isparam":true,"minimum":0.09,"maximum":100.00,"default":100.00,"category":"Throttle","i":32},
"throtramprpm": {"unit":"rpm","value":20000.00,"isparam":true,"minimum":0.00,"maximum":20000.00,"default":20000.00,"category":"Throttle","i":33},
"ampmin": {"unit":"%","value":0.34,"isparam":true,"minimum":0.00,"maximum":100.00,"default":10.00,"category":"Throttle","i":34},
"slipstart": {"unit":"%","value":55.00,"isparam":true,"minimum":10.00,"maximum":100.00,"default":50.00,"category":"Throttle","i":35},
"brknompedal": {"unit":"%","value":-55.00,"isparam":true,"minimum":-100.00,"maximum":0.00,"default":-50.00,"category":"Regen","i":36},
"regenramp": {"unit":"%/10ms","value":3.00,"isparam":true,"minimum":0.09,"maximum":100.00,"default":100.00,"category":"Regen","i":37},
"brknom": {"unit":"%","value":30.00,"isparam":true,"minimum":0.00,"maximum":100.00,"default":30.00,"category":"Regen","i":38},
"brkmax": {"unit":"%","value":-55.00,"isparam":true,"minimum":-100.00,"maximum":0.00,"default":-30.00,"category":"Regen","i":39},
"brkcruise": {"unit":"%","value":-30.00,"isparam":true,"minimum":-100.00,"maximum":0.00,"default":-30.00,"category":"Regen","i":40},
"brkrampstr": {"unit":"Hz","value":40.00,"isparam":true,"minimum":0.00,"maximum":400.00,"default":10.00,"category":"Regen","i":41},
"brkout": {"unit":"%","value":-10.00,"isparam":true,"minimum":-100.00,"maximum":-1.00,"default":-50.00,"category":"Regen","i":42},
"bmslimhigh": {"unit":"%","value":100.00,"isparam":true,"minimum":0.00,"maximum":100.00,"default":50.00,"category":"Derating","i":43},
"bmslimlow": {"unit":"%","value":-20.00,"isparam":true,"minimum":-100.00,"maximum":0.00,"default":-1.00,"category":"Derating","i":44},
"udcmin": {"unit":"V","value":0.00,"isparam":true,"minimum":0.00,"maximum":1000.00,"default":450.00,"category":"Derating","i":45},
"udcmax": {"unit":"V","value":426.00,"isparam":true,"minimum":0.00,"maximum":1000.00,"default":520.00,"category":"Derating","i":46},
"idcmax": {"unit":"A","value":5000.00,"isparam":true,"minimum":0.00,"maximum":5000.00,"default":5000.00,"category":"Derating","i":47},
"idcmin": {"unit":"A","value":-5000.00,"isparam":true,"minimum":-5000.00,"maximum":0.00,"default":-5000.00,"category":"Derating","i":48},
"idckp": {"unit":"dig","value":2.00,"isparam":true,"minimum":0.09,"maximum":20.00,"default":2.00,"category":"Derating","i":49},
"idcflt": {"unit":"dig","value":9.00,"isparam":true,"minimum":0.00,"maximum":11.00,"default":9.00,"category":"Derating","i":50},
"tmphsmax": {"unit":"°C","value":85.00,"isparam":true,"minimum":50.00,"maximum":150.00,"default":85.00,"category":"Derating","i":51},
"tmpmmax": {"unit":"°C","value":300.00,"isparam":true,"minimum":70.00,"maximum":300.00,"default":300.00,"category":"Derating","i":52},
"throtmax": {"unit":"%","value":100.00,"isparam":true,"minimum":0.00,"maximum":100.00,"default":100.00,"category":"Derating","i":53},
"throtmin": {"unit":"%","value":-100.00,"isparam":true,"minimum":-100.00,"maximum":0.00,"default":-100.00,"category":"Derating","i":54},
"iacmax": {"unit":"A","value":5000.00,"isparam":true,"minimum":0.00,"maximum":5000.00,"default":5000.00,"category":"Derating","i":55},
"ifltrise": {"unit":"dig","value":10.00,"isparam":true,"minimum":0.00,"maximum":32.00,"default":10.00,"category":"Derating","i":56},
"ifltfall": {"unit":"dig","value":0.00,"isparam":true,"minimum":0.00,"maximum":32.00,"default":3.00,"category":"Derating","i":57},
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johu
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Re: Tesla Large Drive Unit Support Thread

Post by johu »

With that I can only assume that one of the gate driver faults is either at error OR the connection is dodgy. Please verify that pins 1-6 and 11, 12 of IC10 are HIGH and pin 8 is LOW. If any of the 1-6, 11, 12 are low, check wether they arrive low from the gate drivers or are lost on the way. Most likely on the solder pads of the according connector
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Re: Tesla Large Drive Unit Support Thread

Post by nilsvr »

I measured ic10 and get 0,9V (LOW) on pin1 and therefore 5V (HIGH) at the output Pin8. All other mentioned ones are where they are supposed to be around 5V (only pin3 is a little weak with 3,7V but schould still count as HIGH).

So Pin1 is low eventhough it is supposed to be high and output Pin 8 is high eventhough it is suppsed to be low.

It is not the wiring, the low signal is already coming from the connector on the igbt controller board. Since the rest of the board is covered in that epoxy stuff i can‘t really measure more than at the connector.
Does that mean some hardware (IGBT or IGBT Driver) is dead?

The logic in IC10 is pretty simple to understand but I did not figure out the workings of the IGBT Driver yet...
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