openinverter.org wiki - User contributions [en]

Olimex MOD-WIFI-ESP8266

2022-09-30T19:51:47Z

Ken S: removed accidental hyperlink in example curl command

The Olimex MOD-WIFI-ESP8266 WiFi expansion module is commonly used to provide WiFi connectivity and interface for several inverter controllers including the OpenInverter system. This module connects to the controllers via the UEXT header connector.

=== Flashing Process Overview (e.g for Tesla Charger) ===
[[File:Esp8266-flash.png|thumb]]

# Solder GPIO0 to 0
# Install & open Arduino and setup the code from https://github.com/jsphuebner/esp8266-web-interface
# Flash the code (see below)
# Re-solder GPIO0 to 1
# See a new unprotected WiFi & connect, access web interface at IP 192.168.4.1
====== Step 3 (shortcut) ======
https://raw.githubusercontent.com/espressif/esptool/master/esptool.py

https://openinverter.org/forum/download/file.php?id=9167

<code>python esptool.py --port COM1 --baud 115200 write_flash 0x000000 FSBrowser.ino.modwifi.bin</code>

====== Step 3 (full) ======
https://openinverter.org/forum/viewtopic.php?p=4928#p4928

3.1. Download latest Arduino IDE and install it to PC

3.2. Buy a Weimos D1 mini ESP8266 board with FTDI and get CH340 driver from <nowiki>https://www.wemos.cc/en/latest/d1/d1_mini.html</nowiki> (or use Olimex)

3.3. Inside Arduino IDE install ESP8266

- open the Preferences window

- enter <nowiki>https://arduino.esp8266.com/stable/pack</nowiki> ... index.json into the Additional Board Manager URLs

- open Boards Manager from Tools > Board menu and install esp8266 platform. I select LOLIN D1 R2 mini board, settings are in the pic

3.4. Install ESP8266 Filesystem Uploader

- Download <nowiki>https://github.com/esp8266/arduino-esp8</nowiki> ... n/releases python support files

- extract file to Arduino IDE tools folder like you see here <nowiki>https://randomnerdtutorials.com/install</nowiki> ... duino-ide/

- restart Arduino for changes to come into effect

3.5. Download Johannes Web interface code here: <nowiki>https://github.com/jsphuebner/esp8266-web-interface</nowiki>

- put the code in the same dir as the ino file, default FSBrowser

- make another dir Data inside first and copy everything here again (i am not sure which files are correct, so i just copy them again) this are the SPIFFS

3.6. Connect board to USB and select correct COM port and rest of settings

- if you used a new board you have to select "erase flash: sketch + wifi settings" so the board will erase its password

- click upload and wait for interface to reset the board

- select tools/ESP8266 sketch data upload and wait for the board to reset

- connect to the board and go to <nowiki>http://192.168.4.1/</nowiki> to set your wifi settings inside interface

====== WiFi doesn't show up ======
- in Arduino studio Tools -> Serial Monitor gives debug info of the chip. If the Serial Monitor says "<code>Unknown command sequence"</code> you need to change the TTL

- if GPIO0 is not resoldered, the chip is in programming mode and will not boot from the flash code

====== FileNotFound Error in WebInterface ======
Upload the files from the repository <nowiki>https://github.com/jsphuebner/esp8266-web-interface</nowiki> with below command:<blockquote><syntaxhighlight lang="bash">
#!/bin/bash
IP=192.168.4.1
echo $IP
curl -F 'data=@README.md' http://$IP/edit
curl -F 'data=@ajax-loader.gif' http://$IP/edit
curl -F 'data=@chart.min.js.gz' http://$IP/edit
curl -F 'data=@chartjs-annotation.min.js.gz' http://$IP/edit
curl -F 'data=@gauge.min.js.gz' http://$IP/edit
curl -F 'data=@gauges.html' http://$IP/edit
curl -F 'data=@gauges.js' http://$IP/edit
curl -F 'data=@index.html' http://$IP/edit
curl -F 'data=@index.js' http://$IP/edit
curl -F 'data=@inverter.js' http://$IP/edit
curl -F 'data=@jquery.core.min.js.gz' http://$IP/edit
curl -F 'data=@jquery.knob.min.js.gz' http://$IP/edit
# curl -F 'data=@log.htm' http://$IP/edit
curl -F 'data=@log.html' http://$IP/edit
curl -F 'data=@log.js' http://$IP/edit
curl -F 'data=@refresh.png' http://$IP/edit
curl -F 'data=@remote.html' http://$IP/edit
curl -F 'data=@style.css' http://$IP/edit
curl -F 'data=@syncofs.html' http://$IP/edit
curl -F 'data=@upload.sh' http://$IP/edit
curl -F 'data=@wifi-updated.html' http://$IP/edit
curl -F 'data=@wifi.html' http://$IP/edit
</syntaxhighlight>If the above commands don't work, try removing the single apostrophes around the filename, there seems to be some discrepancies in Curl formatting between Linux and the version included in Windows 10 command prompt.

Example: curl -F data=@wifi.html <nowiki>http://$IP/edit</nowiki></blockquote>Replace $IP with 192.168.4.1

=== Flashing Process for GS450H ===

====== Part 1 : Software and IDE. ======
<nowiki>https://www.arduino.cc/en/software</nowiki>

I've tested this on 1.8.13 so go ahead and grab that and install.

Next you will need to add the ESP8266 to your boards manager.

Tutorial here : https://randomnerdtutorials.com/how-to-install-esp8266-board-arduino-ide/

Go ahead and do that.

Download the WiFi package from my Github :

https://github.com/damienmaguire/Lexus-GS450H-Inverter-Controller/tree/master/WiFi

Copy it to your Arduino sketch directory. Close and reopen Arduino, go to file, sketchbook and it should show up.

Go ahead and open it.

Now you need the correct libraries which is where the fun starts as they are a hot mess in Arduino these days.

I uploaded mine to the repo :

https://github.com/damienmaguire/Lexus-GS450H-Inverter-Controller/tree/master/Software/Libraries

Grab those and unzip both files to your /Arduino/libraries directory.

Next up go to tools and setup your board exactly as shown in the picture.

Close and reopen Arduino then hit the tick box to compile. If you did everything right it will just compile.

====== Part 2 : programming method. ======
You will need a 3v3 level FTDI cable :

https://www.mouser.ie/ProductDetail/FTDI/TTL-232R-3V3/?qs=Xb8IjHhkxj627GFcejHp0Q==

Yes you can use others, no I have no idea if they will work. This is the one I use.

Wire it as per the the attached diagram.

Now, to program the module you need to desolder the GPIO0 jumper and move it to the "0" position.

Back to tools and select your com port.

Click the upload icon (right facing arrow).

When upload is done, unplug and replug the WiFi module from the FTDI cable but do not unplug the USB end from the computer.

Back to tools and click "esp8266 sketch data upload".

when done remove the module and resolder the GPIO0 jumper back to position "1".

Congratulations its now programmed.

====== Precompiled binaries (similar to step 3 shortcut in the tutorial above) ======
attached the compiled binaries for use with the WEMOS D1 Mini, including the SPIFFS filesystem .bin

the SSID is "GS450H-VCU" and the WiFi password is ''`inverter123`''

https://openinverter.org/forum/download/file.php?id=9051

https://openinverter.org/forum/download/file.php?id=9050

=== Common Issues ===

* [[File:ESP8266 communication with DuPont jump leads and without.png|thumb|If experiencing connection issues, try different cables to rule out bad connectors ( apparently common with recent Olimex)]]The settings & partition size in Arduino Studio are easy to get wrong. [https://openinverter.org/forum/viewtopic.php?p=29523#p29523]
* If you get any of: 1) incomplete responses via HTTP 2) patchy WiFi on a logic board 3) parameters from logic board not loading in web interface; you can try powering the ESP8266 from a different source, or connect it via DuPont leads to rule out connector & plug issues (see photographs).
* If you are all out of luck, there are alternative boards discussed here [https://openinverter.org/forum/viewtopic.php?t=2299]

Olimex MOD-WIFI-ESP8266

2022-09-30T19:50:57Z

Ken S: Added an alternative formatting for the curl file upload command that worked in windows 10. It is unclear if this is a curl version issue or a Windows Command Prompt / Linux Console issue.

The Olimex MOD-WIFI-ESP8266 WiFi expansion module is commonly used to provide WiFi connectivity and interface for several inverter controllers including the OpenInverter system. This module connects to the controllers via the UEXT header connector.

=== Flashing Process Overview (e.g for Tesla Charger) ===
[[File:Esp8266-flash.png|thumb]]

# Solder GPIO0 to 0
# Install & open Arduino and setup the code from https://github.com/jsphuebner/esp8266-web-interface
# Flash the code (see below)
# Re-solder GPIO0 to 1
# See a new unprotected WiFi & connect, access web interface at IP 192.168.4.1
====== Step 3 (shortcut) ======
https://raw.githubusercontent.com/espressif/esptool/master/esptool.py

https://openinverter.org/forum/download/file.php?id=9167

<code>python esptool.py --port COM1 --baud 115200 write_flash 0x000000 FSBrowser.ino.modwifi.bin</code>

====== Step 3 (full) ======
https://openinverter.org/forum/viewtopic.php?p=4928#p4928

3.1. Download latest Arduino IDE and install it to PC

3.2. Buy a Weimos D1 mini ESP8266 board with FTDI and get CH340 driver from <nowiki>https://www.wemos.cc/en/latest/d1/d1_mini.html</nowiki> (or use Olimex)

3.3. Inside Arduino IDE install ESP8266

- open the Preferences window

- enter <nowiki>https://arduino.esp8266.com/stable/pack</nowiki> ... index.json into the Additional Board Manager URLs

- open Boards Manager from Tools > Board menu and install esp8266 platform. I select LOLIN D1 R2 mini board, settings are in the pic

3.4. Install ESP8266 Filesystem Uploader

- Download <nowiki>https://github.com/esp8266/arduino-esp8</nowiki> ... n/releases python support files

- extract file to Arduino IDE tools folder like you see here <nowiki>https://randomnerdtutorials.com/install</nowiki> ... duino-ide/

- restart Arduino for changes to come into effect

3.5. Download Johannes Web interface code here: <nowiki>https://github.com/jsphuebner/esp8266-web-interface</nowiki>

- put the code in the same dir as the ino file, default FSBrowser

- make another dir Data inside first and copy everything here again (i am not sure which files are correct, so i just copy them again) this are the SPIFFS

3.6. Connect board to USB and select correct COM port and rest of settings

- if you used a new board you have to select "erase flash: sketch + wifi settings" so the board will erase its password

- click upload and wait for interface to reset the board

- select tools/ESP8266 sketch data upload and wait for the board to reset

- connect to the board and go to <nowiki>http://192.168.4.1/</nowiki> to set your wifi settings inside interface

====== WiFi doesn't show up ======
- in Arduino studio Tools -> Serial Monitor gives debug info of the chip. If the Serial Monitor says "<code>Unknown command sequence"</code> you need to change the TTL

- if GPIO0 is not resoldered, the chip is in programming mode and will not boot from the flash code

====== FileNotFound Error in WebInterface ======
Upload the files from the repository <nowiki>https://github.com/jsphuebner/esp8266-web-interface</nowiki> with below command:<blockquote><syntaxhighlight lang="bash">
#!/bin/bash
IP=192.168.4.1
echo $IP
curl -F 'data=@README.md' http://$IP/edit
curl -F 'data=@ajax-loader.gif' http://$IP/edit
curl -F 'data=@chart.min.js.gz' http://$IP/edit
curl -F 'data=@chartjs-annotation.min.js.gz' http://$IP/edit
curl -F 'data=@gauge.min.js.gz' http://$IP/edit
curl -F 'data=@gauges.html' http://$IP/edit
curl -F 'data=@gauges.js' http://$IP/edit
curl -F 'data=@index.html' http://$IP/edit
curl -F 'data=@index.js' http://$IP/edit
curl -F 'data=@inverter.js' http://$IP/edit
curl -F 'data=@jquery.core.min.js.gz' http://$IP/edit
curl -F 'data=@jquery.knob.min.js.gz' http://$IP/edit
# curl -F 'data=@log.htm' http://$IP/edit
curl -F 'data=@log.html' http://$IP/edit
curl -F 'data=@log.js' http://$IP/edit
curl -F 'data=@refresh.png' http://$IP/edit
curl -F 'data=@remote.html' http://$IP/edit
curl -F 'data=@style.css' http://$IP/edit
curl -F 'data=@syncofs.html' http://$IP/edit
curl -F 'data=@upload.sh' http://$IP/edit
curl -F 'data=@wifi-updated.html' http://$IP/edit
curl -F 'data=@wifi.html' http://$IP/edit
</syntaxhighlight>If the above commands don't work, try removing the single apostrophes around the filename, there seems to be some discrepancies in Curl formatting between Linux and the version included in Windows 10 command prompt.

Example: curl -F data=@wifi.html http://$IP/edit</blockquote>Replace $IP with 192.168.4.1

=== Flashing Process for GS450H ===

====== Part 1 : Software and IDE. ======
<nowiki>https://www.arduino.cc/en/software</nowiki>

I've tested this on 1.8.13 so go ahead and grab that and install.

Next you will need to add the ESP8266 to your boards manager.

Tutorial here : https://randomnerdtutorials.com/how-to-install-esp8266-board-arduino-ide/

Go ahead and do that.

Download the WiFi package from my Github :

https://github.com/damienmaguire/Lexus-GS450H-Inverter-Controller/tree/master/WiFi

Copy it to your Arduino sketch directory. Close and reopen Arduino, go to file, sketchbook and it should show up.

Go ahead and open it.

Now you need the correct libraries which is where the fun starts as they are a hot mess in Arduino these days.

I uploaded mine to the repo :

https://github.com/damienmaguire/Lexus-GS450H-Inverter-Controller/tree/master/Software/Libraries

Grab those and unzip both files to your /Arduino/libraries directory.

Next up go to tools and setup your board exactly as shown in the picture.

Close and reopen Arduino then hit the tick box to compile. If you did everything right it will just compile.

====== Part 2 : programming method. ======
You will need a 3v3 level FTDI cable :

https://www.mouser.ie/ProductDetail/FTDI/TTL-232R-3V3/?qs=Xb8IjHhkxj627GFcejHp0Q==

Yes you can use others, no I have no idea if they will work. This is the one I use.

Wire it as per the the attached diagram.

Now, to program the module you need to desolder the GPIO0 jumper and move it to the "0" position.

Back to tools and select your com port.

Click the upload icon (right facing arrow).

When upload is done, unplug and replug the WiFi module from the FTDI cable but do not unplug the USB end from the computer.

Back to tools and click "esp8266 sketch data upload".

when done remove the module and resolder the GPIO0 jumper back to position "1".

Congratulations its now programmed.

====== Precompiled binaries (similar to step 3 shortcut in the tutorial above) ======
attached the compiled binaries for use with the WEMOS D1 Mini, including the SPIFFS filesystem .bin

the SSID is "GS450H-VCU" and the WiFi password is ''`inverter123`''

https://openinverter.org/forum/download/file.php?id=9051

https://openinverter.org/forum/download/file.php?id=9050

=== Common Issues ===

* [[File:ESP8266 communication with DuPont jump leads and without.png|thumb|If experiencing connection issues, try different cables to rule out bad connectors ( apparently common with recent Olimex)]]The settings & partition size in Arduino Studio are easy to get wrong. [https://openinverter.org/forum/viewtopic.php?p=29523#p29523]
* If you get any of: 1) incomplete responses via HTTP 2) patchy WiFi on a logic board 3) parameters from logic board not loading in web interface; you can try powering the ESP8266 from a different source, or connect it via DuPont leads to rule out connector & plug issues (see photographs).
* If you are all out of luck, there are alternative boards discussed here [https://openinverter.org/forum/viewtopic.php?t=2299]

Tesla Model 3 Charger/DCDC ("PCS")

2022-08-22T16:43:49Z

Ken S: Added a section on physical connections to the PCS and PCS controller, based on information provided by Damien in the Model 3 PCS controller support thread.

== Overview ==
The Tesla Model 3 has a "Power Conversion System" (also known as the "PCS") which contains both a 10kW AC charger and a ??W DCDC converter. The PCS is located inside the "Penthouse" part of the main traction battery system.

== Learning/Resources ==
Video - The Tesla Project : Model 3 PCS First Look - https://youtu.be/_TYvSmDJSPQ

Video - Tesla Model 3 Power Conversion System - https://youtu.be/3ARHdRwfxjY

OpenInverter PCS overview/tech thread: https://openinverter.org/forum/viewtopic.php?f=10&t=171

OpenInverter PCS controller support thread: https://openinverter.org/forum/viewtopic.php?p=27744#p27744

Damien's GitHib: https://github.com/damienmaguire/Tesla-Model-3-Charger

== Hardware ==

=== Controller ===
Damien from EVBMW has designed a control solution which is open hardware, but closed software. Design files for the controller hardware are available on Damien's GitHub [https://github.com/damienmaguire/Tesla-Model-3-Charger here]. Licenses for the software are available through Johannes' OI webstore [https://openinverter.org/shop/index.php?route=product/product&path=17&product_id=67 here]. Controllers are also available as a fully-built kit (with pre-loaded software) on the EVBWM webstore [https://www.evbmw.com/index.php/evbmw-webshop/tesla-boards/tesla-model-3-pcs-con here].

The PCS comes with different firmware versions some of which don't currently work with the above controller. We are in search of a solution.

=== Data Connectors ===
''EDITOR'S NOTE: my research shows some conflicting/different part numbers mentioned - would appreciate some clarification here once validated''

As per: https://openinverter.org/forum/viewtopic.php?p=26614&sid=24f0c02f437aeba37d4fc698d0ce54e6#p26614<blockquote>''The connector used for communications with the PCS :''

''https://www.te.com/global-en/product-1379662-5.html''

[https://www.mouser.ie/ProductDetail/TE-Connectivity-AMP/1379662-1?qs=%2Fha2pyFaduhhLY7GkruXdss4LW5fFjnNe6YzKwrJA1Y%3D ''https://www.mouser.ie/ProductDetail/TE- ... KwrJA1Y%3D'']

''Pins: [https://www.mouser.ie/ProductDetail/TE-Connectivity/1801069-2?qs=sGAEpiMZZMvlX3nhDDO4AIlVXMSSZRpGH8WODUA4Ad4%3D 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.''</blockquote>However, as per: https://github.com/muehlpower/EV-FFB, there is also mention of 1318774-1 (white) or 1318774-2 (black) for the comms/data connector.

=== Power Connectors ===
The power-side connector assemblies are not widely available. The housings are a Tesla internal part (photos/part numbers [https://openinverter.org/forum/viewtopic.php?p=27744#p27744 here]), however, 3D printable housings have been made available [https://github.com/muehlpower/EV-FFB here]. The terminals also aren't widely available, but are known. As per https://github.com/muehlpower/EV-FFB:<blockquote>''The contacts for 400V are Uni F630 from MTA, part number 1107940. For 12V Kostal PLK 14.5, part number 23124734300. The connector for the data is from TE connectivity, part number 1318774-1 for white or 1318774-2 for black.''</blockquote>

=== Connections ===
[[File:Tesla PCS Connection diagram 8162022.png|thumb]]
The minimum wiring needed to wake the PCS:

# PCS controller connected to PCS via 12-way X420
# PCS controller is powered via 20-way +12V input pin and grounded to chassis via 20-way ground pin
# +12v and Chassis ground applied to PCS 12v Connector input terminal
# Chassis ground on the PCS case

The minimum recommended HV DC battery voltage for testing is 250V (This needs to be confirmed)
[[Category:OEM]] [[Category:Tesla]] [[Category:Charger]] [[Category:DC/DC]]

File:Tesla PCS Connection diagram 8162022.png

2022-08-22T16:34:35Z

Ken S:

Basic wiring diagram for using the Tesla PCS