openinverter.org wiki - User contributions [en]

Tesla CAD Models

2026-02-18T03:35:52Z

Nubster:

[https://www.westside-ev.com/s/LDU-Inverter-Stand.stl Tesla LDU Inverter Stand]

[https://www.westside-ev.com/s/rsdu_reverse_oilpump_pickup.stl Tesla RSDU Reverse Oil Pump Pickup]

[https://www.westside-ev.com/s/fsdu_reverse_oilpump_bracket.step Tesla FSDU Reverse Oil Pump Bracket]

[https://www.westside-ev.com/s/Tesla_SDU_Molex_Receptacle.stl Tesla SDU Molex MX150 Replacement Receptacle]

Tesla CAD Models

2026-02-18T03:31:38Z

Nubster: Added STL link

[https://www.westside-ev.com/s/LDU-Inverter-Stand.stl Tesla LDU Inverter Stand]

Tesla Model S/X GEN2 Charger

2024-11-28T21:31:42Z

Nubster: /* Replacement board connectors */ added link

==Overview==
[[File:Gen2.jpg|thumb|tesla gen2 ac charger]]
[[File:Tesla gen2 xray.png|thumb|Tesla Gen2 X-Ray]]

The Tesla GEN2 on-board charger (OBC) is a single/three phase 10kW AC charger that was fitted in the Model S from approx. Oct2013<ref>https://teslamotorsclub.com/tmc/posts/6560948/</ref> until it was replaced in the 2016 'facelift' model with GEN3. It was the first Tesla OBC capable of fully utilizing external 3-phase AC; [[Tesla Model S GEN1 Charger|previous Tesla OBCs]] lacked the external wiring for three phases.

One or two GEN2 chargers are installed beneath the rear seats in the Model S for AC charging.

The charger is made up of three 3.3 kw modules, each sitting on a liquid cooling plate. This assembly enables both single and multi phase AC charging.

==Important Considerations==

===Output Voltage Range===
{| class="wikitable" style="background-color:#ffffcc;" cellpadding="10"
|'''HEED DAMIEN'S WARNING:'''<ref>https://openinverter.org/forum/viewtopic.php?p=9994#p9994</ref>
"[https://openinverter.org/forum/viewtopic.php?f=10&t=78&p=9994#p9994 Running a Tesla charger at much under 200v dc will cause it to explode. Yes I know the label says 50 to 450v but it lies. Yes I blew one up discovering this.]"
|}

===Supported Tesla Part Numbers (TPN)===
It has been found that early revision units will not work with the OI control boards.<ref>https://openinverter.org/forum/viewtopic.php?t=932</ref>

TPNs to avoid:

*1014963-05-B and 1014963-05-C

TPNs tested and known good:

*1014963-00-C/E/F/J/K/L
**1014963-00-C <ref>https://openinverter.org/forum/viewtopic.php?p=34710#p34710 and also by Lars on June 25th 2024</ref>
**1014963-00-G is likely also good, just wasn't mentioned by name in the referenced thread

=== Supported Software Revisions ===
At this time, it is not known why but it appears that some firmware revisions of this charger will have problems with maintaining a steady charge. Symptoms of this can be either surging (current goes up, drops to near zero, then surges back) or modules coming online singly followed by all modules going offline, repeat forever. In either case, charge power will be limited. We do not yet know what, exactly, is causing this. However, it is confirmed that swapping charger units but keeping the OI control board can produce working results.

===Cooling===
The direction of flow in the cooling plate does not seem to matter.<ref>https://openinverter.org/forum/viewtopic.php?p=2030#p2030</ref> The charger should likely be on the same cooling loop as the batteries themselves. This coolant loop should be separate from the loop with the motor and inverter (they get far too hot.) Limited testing (esp 110V, 1kw) can be done without the coolant lines hooked up. However, it would be unwise to attempt 10kw charging for any length of time without liquid cooling.

==Replacement Control Boards==
Replacement control board https://github.com/damienmaguire/Tesla-Charger

v5 kit: https://www.evbmw.com/index.php/evbmw-webshop/tesla-boards/tesla-gen-2-charger-logic-board-kit

v5 partially built board: https://www.evbmw.com/index.php/evbmw-webshop/tesla-boards/tesla-gen-2-charger-logic-board-partially-built

github: https://github.com/damienmaguire/Tesla-Charger

=== Charger Connections ===
[[File:Tesla Charger Logic connections.jpg|none|thumb|607x607px|
{| class="wikitable"
!A1
!A2
!A3
!A4
!A5
!
!B1
!B2
!B3
!B4
! B5
!B6
|-
|OUT2 - AC present
|
|D1 - enable
|
|
|
|12V supply
|
|
|CANH
|Control Pilot
|
|-
!A6
!A7
! A8
!A9
!A10
!
!B7
!B8
!B9
!B10
!B11
!B12
|-
|OUT1 - HV enable
|
|
|
|D2 - 3p
|
| GND
|
|
|CANL
|Proximity
|
|}
The outputs will not output 12v, they are low side switches. If you require a 12v ac present signal then use a relay with its coil switched from the relevant pin. [https://raw.githubusercontent.com/damienmaguire/Tesla-Charger/master/V5/Charger_Gen2_V5aB3%20-%20Schematic.pdf wiring diagram][[File:AC DC Connections.jpg|left|thumb|600x600px]]]]

====Connector part numbers====
AC and DC power connections (Molex Sabre series):

*housing: 044441-2006
*pins: 043375-3001 (18-20AWG), 043375-0001 (14-16AWG)

Logic connectors (Molex MX150L series):

*housing: 10-way 19418-0014, 12-way 19418-0026
*pins: 33012-2002 (18-20AWG), 33012-2001 (14-16AWG)

=== Replacement board connectors ===
If you can desolder 24 pin SMD connector off of the OEM control board otherwise to order 24 pin connector from Mouser P/N is:

* [https://www.mouser.com/ProductDetail/JST-Automotive/SM24B-CPTK-1A-TBL?qs=wBn5QRdTcLhQ%2FCp3E8a%2FyA%3D%3D SM24B-CPTK-1A-TB(L)]

The 30 pin connector is very difficult to desolder and resolder. Replacement P/Ns are:

* [https://www.mouser.com/ProductDetail/Samtec/IPS1-115-01-S-D-PL?qs=PB6%2FjmICvI17nbB5SDGUsw%3D%3D IPS1-115-01-S-D-PL], SAMTEC - IPS1-115-01-S-D-PL - SOCKET, 2.54MM, 2X15WAY
** NOTE: One of the pins is missing from this connector variant, but according to [https://openinverter.org/forum/viewtopic.php?p=27697&hilit=charger+pin+missing#p27697 this forum post], it's ok as long as you solder it in the correct orientation.
* [https://www.mouser.com/ProductDetail/Samtec/IPS1-115-01-L-D?qs=PB6%2FjmICvI3sN4zSP4IXGw%3D%3D IPS1-115-01-L-D], SAMTEC
** Has all 30 pins.

===Programming===
You'll need a ST-LINK/V2 smt32 programmer. Unofficial ones are cheaply available from amazon and ebay.

*ST-LINK programming utility: https://www.st.com/en/development-tools/stsw-link004.html
* stm32_loader.hex https://openinverter.org/forum/viewtopic.php?f=7&t=1119
'''Two options:'''
#Charger_gen2_v5.hex https://github.com/damienmaguire/Tesla-Charger/tree/master/V5/Software/Binary
#openinverter style firmware https://openinverter.org/forum/viewtopic.php?t=1323 (only available via patreon for next few weeks)

Click "Target --> Connect" from top menu. You want to see the screen get filled with a data dump of symbols. In the upper right of the screen you can see it identified the device.

In the main viewing window are multiple tabs, click the "Binary File" tab to select it.

This will ask to open a file, you choose: "stm32_loader.hex" from openinverter.org, download ahead of time. This will change what shows up in the viewing window.

Click "Target --> Program and Verify" from the top menu. This pops up a window, and you can probably just click "Start" on that window. This programs the STM32 chip with the stm32_loader.hex file.

The STM32 on your v5 gen2 Tesla charger Board can now load other files.

You can close the stm32_loader.hex tab, and go back to the "Binary File" tab, which will ask to open another file.

You choose: "Charger_Gen2_v5.hex"

Same as last time, click "Target --> Program and Verify" from the top menu. And click Start.

The STM32 on your v5 gen2 Tesla charger Board now also has the software to run.

You are now done with the ST-Link USB dongle, it's no longer needed.

Future updates can be done via WiFi. (must have esp8266 WiFi module programed https://openinverter.org/forum/viewtopic.php?f=5&t=8 )

=== External CAN bus===
[[File:Gen2 Charger V5aB2 logic board.jpg|thumb|Gen2 Charger V5aB2 logic board with CAN wired to external pins]]
The V5aB2 version of the board has no connection to the external CAN bus (V5aB3 has) but you can add it with two bodge wires as shown in the picture. You will find CANH and CANL on the 3 pin header underneath the WiFi module. Route them over to CONN6 as shown. CONN2.1 (CANH) is connected to CONN6.24, CONN2.2 (CANL) to CONN6.26.

Revision V5aB3 does not need this modification. On Revision V5aB3 you '''MUST''' close the solder jumper unless your charger is on an already terminated bus (that is, if the bus already has 2 termination resistors, one on each end, and measures 60 ohms with all devices powered off). If you do not use the external CAN, terminate the bus. If you have only two devices on the bus, terminate the bus. If you aren't sure, double check. '''Bus termination is important.'''

If you attach to the external CAN bus, be aware that all internal CAN traffic is also seen on the external CAN bus. The following IDs are already used and mustn't used by any other device on the bus:

207, 209, 20b, 217, 219, 21b, 227, 229, 22b, 237, 239, 23b, 247, 249, 24b, 327, 329, 32b, 347, 349, 34b, 357, 359, 35b, 367, 368, 369, 36b, 377, 379, 37b, 537, 539, 53b, 717, 719, 71b.

====Functionality of external CAN bus====
With the CAN bus now available externally you can remote control your charger via CAN and also receive some values from it. The mapping is similar to the CHAdeMO CAN protocol. The feature is only available in the commercial firmware.
{| class="wikitable"
|+Charger CAN protocol - up to version 1.06.R
!ID
!Direction
!Byte 0
! Byte 1
!Byte 2
!Byte 3
!Byte 4
! Byte 5
! Byte 6
!Byte 7
|-
|0x102
|Receive by charger
|
|DC voltage limit MSB
|DC voltage limit LSB
| DC current set point
|==1 enable charging
|SoC
|
|
|-
|0x108
|Transmit by charger
|Version=0
|Max DC voltage MSB
| Max DC voltage LSB
|Max DC current
|
|
|
|
|-
|0x109
|Transmit by charger
|Version=0
|DC voltage MSB
|DC voltage LSB
|DC current
|''0 when off, 5 when charging''

|
|
|
|}
Example: transmit "0x102 # 0 0x1 0x86 0x14 0x1 50 0 0" to enable charging up to a voltage of 390V and a DC current of 20A, report SoC of 50%

{| class="wikitable"
|+Charger CAN protocol - after version 1.06.R
!ID
!Direction
!Byte 0
!Byte 1
!Byte 2
!Byte 3
!Byte 4
!Byte 5
!Byte 6
!Byte 7
|-
| 0x102
|Receive by charger
|
|DC voltage limit MSB
|DC voltage limit LSB
|DC current set point
|
|==1 enable charging
|SoC
|
|-
|0x108
|Transmit by charger
|Version=0
|Max DC voltage MSB
| Max DC voltage LSB
|Max DC current
|
|
|
|
|-
|0x109
| Transmit by charger
|Version=0
|DC voltage MSB
|DC voltage LSB
|DC current
|
|0 when off, 5 when charging
|
|
|}
LR: Personally I think the data for DC voltage limit is incorrect. The above states Motorola but only when I set all signals (so not only DC voltage limit as also the start bit count (sometimes) varies) to Intel it works for me.[[File:Parameter view of commercial firmware.png|thumb|Parameter view of commercial firmware]]

===openinverter style charger firmware===
In addition to the open source firmware there is also an openinverter style firmware. It adds advanced features:
*Support for the standard open inverter web interface
*Parameter handling as known from the inverter firmware (see picture)
*Spot value handling like inverter including plotting, gauges, and logging
*Over the air update like inverter
*DC current control
* CAN control as described above
The firmware requires the board to be flashed with [https://github.com/jsphuebner/tumanako-inverter-fw-bootloader/releases stm32_loader.hex]. An Olimex MOD-ESP8266 must be programmed with the [https://github.com/jsphuebner/esp8266-web-interface openinverter web interface]. See [[Olimex MOD-WIFI-ESP8266]] and [https://openinverter.org/forum/viewtopic.php?f=5&t=8 this forum thread] for flashing instructions. With that done, future updates will happen via the web interface.

The firmware will soon be fully published and is only available via patreon for now: https://www.patreon.com/openinverter

====Connecting to the Web interface====
Depending on the version of your Olimex wifi dongle they are "open" or you need a password to connect.

By default you can connect to the network (Access Point) and browse to: '''192.168.4.1'''

By default all charger kits will have '''SSID''' : charger '''PASSWORD''' : charger123

''Note: Its recommend that you change it. Nobody wants to drive and have some joker with a phone finding this information and accessing your charger.''

'''Missing IC4 Chip'''

According to [https://openinverter.org/forum/viewtopic.php?p=43750&hilit=ic4#p43750 this forum post], IC4 used to be populated with a USB to serial FTDI chip. However, on the latest boards, all settings are configured via wifi so it is no longer needed.
[[File:Gen2ChargerBoard.jpg|alt=Image of Tesla Gen2 charger board with missing IC4 chip|thumb|Tesla Gen2 charger board with missing IC4 chip]]

====Registration====
This step is no longer needed as the firmware will soon be published. It is already available on patreon: https://www.patreon.com/openinverter

If you bought a fully assembled V5aB3 board from the EVBMW webshop you can skip this step.

=== Latest Software for V5 boards and later ===
[[Tesla Model S/Tesla Gen23 V5 Software]]

==Additional Resources==

Videos by Damien Maguire showing internals of the charger, CAN IDs, wiring, and development of the board:

[https://www.youtube.com/watch?v=LqJ7HhS65po The Tesla Project : 10 Kw Gen 2 Charger]

[https://www.youtube.com/watch?v=ULadBnl7wgM The Tesla Project : Charger Progress]

[https://www.youtube.com/watch?v=mOIgp3QFg78 The Tesla Project : 10kW Charger Charging]

[https://www.youtube.com/watch?v=BG4kYsoHe54 The Tesla Project : More Charger Hacking]

[https://www.youtube.com/watch?v=bPLqXCiArVM The Tesla Project : Charger 10kw Run]

A 15 min intro from a user perspective: https://www.youtube.com/watch?v=ibtr6v1k0cA

==Common Issues==

*The Tesla chargers are very sensitive to grounding. The case MUST be connected to vehicle 12v ground AND evse earth/ground when charging. [https://openinverter.org/forum/viewtopic.php?p=3890#p3890]
*With V5aB2, If you do NOT use the external CAN bus or are not properly terminated, '''remember to close the solder jumper''' next to R1 under the WiFi module. When in doubt, check the resistance of the CAN bus with all devices off. It should be 60 ohms ideally. If you are not using the external CAN then it should be 120 ohms.
*People had problems with unreliable connectivity between ESP8266 & the charger board [https://openinverter.org/wiki/Olimex_MOD-WIFI-ESP8266#Common_Issues]
*Firmware '''1.09''' and '''1.10''' can lose the CAN map, making the logic board go silent, reset instructions here: [https://openinverter.org/forum/viewtopic.php?p=40617&sid=e2369fea2b502a419f55e5aac10fe169#p40617]
*If a module within the charger is enabled (and all three are enabled by default) then it '''MUST''' see AC and DC voltage when charging starts. If it does not then no current will flow on any module. So, triple check your wiring before starting. It can be easy to mix up the line and neutral wires of the AC input. This will not blow up anything but it won't work either. Mixing up the DC wires is a recipe for a bad time.
*Some chargers are just raised wrong. As covered above, for reasons we don't know, some modules will simply refuse to work properly. Most often this will happen to chargers that were previously used in super charger stations but it can happen to chargers that were pulled from Model S cars as well. There is not yet any known fix for this. If it happens the only current solution is a different charger or you live with slow charging.
*Did you set the D1 enable pin to be high (+12v?) It must be high in '''ANY''' mode in order for charging to start. It is OK to tie it to the +12 incoming power if you are using something like Type2 where charging is controlled by the proximity and control pilot signals.

==Errata==
Charger Dimensions: 500x300x100mm

More specific dimensions and CAD info here: https://openinverter.org/forum/viewtopic.php?p=3641#p3641CAD

==Notes==
[[Category:OEM]]
[[Category:Tesla]]
[[Category:Charger]]

<references />

Tesla Model S/X GEN2 Charger

2024-11-28T21:29:06Z

Nubster: /* Replacement board connectors */

==Overview==
[[File:Gen2.jpg|thumb|tesla gen2 ac charger]]
[[File:Tesla gen2 xray.png|thumb|Tesla Gen2 X-Ray]]

The Tesla GEN2 on-board charger (OBC) is a single/three phase 10kW AC charger that was fitted in the Model S from approx. Oct2013<ref>https://teslamotorsclub.com/tmc/posts/6560948/</ref> until it was replaced in the 2016 'facelift' model with GEN3. It was the first Tesla OBC capable of fully utilizing external 3-phase AC; [[Tesla Model S GEN1 Charger|previous Tesla OBCs]] lacked the external wiring for three phases.

One or two GEN2 chargers are installed beneath the rear seats in the Model S for AC charging.

The charger is made up of three 3.3 kw modules, each sitting on a liquid cooling plate. This assembly enables both single and multi phase AC charging.

==Important Considerations==

===Output Voltage Range===
{| class="wikitable" style="background-color:#ffffcc;" cellpadding="10"
|'''HEED DAMIEN'S WARNING:'''<ref>https://openinverter.org/forum/viewtopic.php?p=9994#p9994</ref>
"[https://openinverter.org/forum/viewtopic.php?f=10&t=78&p=9994#p9994 Running a Tesla charger at much under 200v dc will cause it to explode. Yes I know the label says 50 to 450v but it lies. Yes I blew one up discovering this.]"
|}

===Supported Tesla Part Numbers (TPN)===
It has been found that early revision units will not work with the OI control boards.<ref>https://openinverter.org/forum/viewtopic.php?t=932</ref>

TPNs to avoid:

*1014963-05-B and 1014963-05-C

TPNs tested and known good:

*1014963-00-C/E/F/J/K/L
**1014963-00-C <ref>https://openinverter.org/forum/viewtopic.php?p=34710#p34710 and also by Lars on June 25th 2024</ref>
**1014963-00-G is likely also good, just wasn't mentioned by name in the referenced thread

=== Supported Software Revisions ===
At this time, it is not known why but it appears that some firmware revisions of this charger will have problems with maintaining a steady charge. Symptoms of this can be either surging (current goes up, drops to near zero, then surges back) or modules coming online singly followed by all modules going offline, repeat forever. In either case, charge power will be limited. We do not yet know what, exactly, is causing this. However, it is confirmed that swapping charger units but keeping the OI control board can produce working results.

===Cooling===
The direction of flow in the cooling plate does not seem to matter.<ref>https://openinverter.org/forum/viewtopic.php?p=2030#p2030</ref> The charger should likely be on the same cooling loop as the batteries themselves. This coolant loop should be separate from the loop with the motor and inverter (they get far too hot.) Limited testing (esp 110V, 1kw) can be done without the coolant lines hooked up. However, it would be unwise to attempt 10kw charging for any length of time without liquid cooling.

==Replacement Control Boards==
Replacement control board https://github.com/damienmaguire/Tesla-Charger

v5 kit: https://www.evbmw.com/index.php/evbmw-webshop/tesla-boards/tesla-gen-2-charger-logic-board-kit

v5 partially built board: https://www.evbmw.com/index.php/evbmw-webshop/tesla-boards/tesla-gen-2-charger-logic-board-partially-built

github: https://github.com/damienmaguire/Tesla-Charger

=== Charger Connections ===
[[File:Tesla Charger Logic connections.jpg|none|thumb|607x607px|
{| class="wikitable"
!A1
!A2
!A3
!A4
!A5
!
!B1
!B2
!B3
!B4
! B5
!B6
|-
|OUT2 - AC present
|
|D1 - enable
|
|
|
|12V supply
|
|
|CANH
|Control Pilot
|
|-
!A6
!A7
! A8
!A9
!A10
!
!B7
!B8
!B9
!B10
!B11
!B12
|-
|OUT1 - HV enable
|
|
|
|D2 - 3p
|
| GND
|
|
|CANL
|Proximity
|
|}
The outputs will not output 12v, they are low side switches. If you require a 12v ac present signal then use a relay with its coil switched from the relevant pin. [https://raw.githubusercontent.com/damienmaguire/Tesla-Charger/master/V5/Charger_Gen2_V5aB3%20-%20Schematic.pdf wiring diagram][[File:AC DC Connections.jpg|left|thumb|600x600px]]]]

====Connector part numbers====
AC and DC power connections (Molex Sabre series):

*housing: 044441-2006
*pins: 043375-3001 (18-20AWG), 043375-0001 (14-16AWG)

Logic connectors (Molex MX150L series):

*housing: 10-way 19418-0014, 12-way 19418-0026
*pins: 33012-2002 (18-20AWG), 33012-2001 (14-16AWG)

=== Replacement board connectors ===
If you can desolder 24 pin SMD connector off of the OEM control board otherwise to order 24 pin connector from Mouser P/N is:

* SM24B-CPTK-1A-TB(L)

The 30 pin connector is very difficult to desolder and resolder. Replacement P/Ns are:

* [https://www.mouser.com/ProductDetail/Samtec/IPS1-115-01-S-D-PL?qs=PB6%2FjmICvI17nbB5SDGUsw%3D%3D IPS1-115-01-S-D-PL], SAMTEC - IPS1-115-01-S-D-PL - SOCKET, 2.54MM, 2X15WAY
** NOTE: One of the pins is missing from this connector variant, but according to [https://openinverter.org/forum/viewtopic.php?p=27697&hilit=charger+pin+missing#p27697 this forum post], it's ok as long as you solder it in the correct orientation.
* [https://www.mouser.com/ProductDetail/Samtec/IPS1-115-01-L-D?qs=PB6%2FjmICvI3sN4zSP4IXGw%3D%3D IPS1-115-01-L-D], SAMTEC
** Has all 30 pins.

===Programming===
You'll need a ST-LINK/V2 smt32 programmer. Unofficial ones are cheaply available from amazon and ebay.

*ST-LINK programming utility: https://www.st.com/en/development-tools/stsw-link004.html
* stm32_loader.hex https://openinverter.org/forum/viewtopic.php?f=7&t=1119
'''Two options:'''
#Charger_gen2_v5.hex https://github.com/damienmaguire/Tesla-Charger/tree/master/V5/Software/Binary
#openinverter style firmware https://openinverter.org/forum/viewtopic.php?t=1323 (only available via patreon for next few weeks)

Click "Target --> Connect" from top menu. You want to see the screen get filled with a data dump of symbols. In the upper right of the screen you can see it identified the device.

In the main viewing window are multiple tabs, click the "Binary File" tab to select it.

This will ask to open a file, you choose: "stm32_loader.hex" from openinverter.org, download ahead of time. This will change what shows up in the viewing window.

Click "Target --> Program and Verify" from the top menu. This pops up a window, and you can probably just click "Start" on that window. This programs the STM32 chip with the stm32_loader.hex file.

The STM32 on your v5 gen2 Tesla charger Board can now load other files.

You can close the stm32_loader.hex tab, and go back to the "Binary File" tab, which will ask to open another file.

You choose: "Charger_Gen2_v5.hex"

Same as last time, click "Target --> Program and Verify" from the top menu. And click Start.

The STM32 on your v5 gen2 Tesla charger Board now also has the software to run.

You are now done with the ST-Link USB dongle, it's no longer needed.

Future updates can be done via WiFi. (must have esp8266 WiFi module programed https://openinverter.org/forum/viewtopic.php?f=5&t=8 )

=== External CAN bus===
[[File:Gen2 Charger V5aB2 logic board.jpg|thumb|Gen2 Charger V5aB2 logic board with CAN wired to external pins]]
The V5aB2 version of the board has no connection to the external CAN bus (V5aB3 has) but you can add it with two bodge wires as shown in the picture. You will find CANH and CANL on the 3 pin header underneath the WiFi module. Route them over to CONN6 as shown. CONN2.1 (CANH) is connected to CONN6.24, CONN2.2 (CANL) to CONN6.26.

Revision V5aB3 does not need this modification. On Revision V5aB3 you '''MUST''' close the solder jumper unless your charger is on an already terminated bus (that is, if the bus already has 2 termination resistors, one on each end, and measures 60 ohms with all devices powered off). If you do not use the external CAN, terminate the bus. If you have only two devices on the bus, terminate the bus. If you aren't sure, double check. '''Bus termination is important.'''

If you attach to the external CAN bus, be aware that all internal CAN traffic is also seen on the external CAN bus. The following IDs are already used and mustn't used by any other device on the bus:

207, 209, 20b, 217, 219, 21b, 227, 229, 22b, 237, 239, 23b, 247, 249, 24b, 327, 329, 32b, 347, 349, 34b, 357, 359, 35b, 367, 368, 369, 36b, 377, 379, 37b, 537, 539, 53b, 717, 719, 71b.

====Functionality of external CAN bus====
With the CAN bus now available externally you can remote control your charger via CAN and also receive some values from it. The mapping is similar to the CHAdeMO CAN protocol. The feature is only available in the commercial firmware.
{| class="wikitable"
|+Charger CAN protocol - up to version 1.06.R
!ID
!Direction
!Byte 0
! Byte 1
!Byte 2
!Byte 3
!Byte 4
! Byte 5
! Byte 6
!Byte 7
|-
|0x102
|Receive by charger
|
|DC voltage limit MSB
|DC voltage limit LSB
| DC current set point
|==1 enable charging
|SoC
|
|
|-
|0x108
|Transmit by charger
|Version=0
|Max DC voltage MSB
| Max DC voltage LSB
|Max DC current
|
|
|
|
|-
|0x109
|Transmit by charger
|Version=0
|DC voltage MSB
|DC voltage LSB
|DC current
|''0 when off, 5 when charging''

|
|
|
|}
Example: transmit "0x102 # 0 0x1 0x86 0x14 0x1 50 0 0" to enable charging up to a voltage of 390V and a DC current of 20A, report SoC of 50%

{| class="wikitable"
|+Charger CAN protocol - after version 1.06.R
!ID
!Direction
!Byte 0
!Byte 1
!Byte 2
!Byte 3
!Byte 4
!Byte 5
!Byte 6
!Byte 7
|-
| 0x102
|Receive by charger
|
|DC voltage limit MSB
|DC voltage limit LSB
|DC current set point
|
|==1 enable charging
|SoC
|
|-
|0x108
|Transmit by charger
|Version=0
|Max DC voltage MSB
| Max DC voltage LSB
|Max DC current
|
|
|
|
|-
|0x109
| Transmit by charger
|Version=0
|DC voltage MSB
|DC voltage LSB
|DC current
|
|0 when off, 5 when charging
|
|
|}
LR: Personally I think the data for DC voltage limit is incorrect. The above states Motorola but only when I set all signals (so not only DC voltage limit as also the start bit count (sometimes) varies) to Intel it works for me.[[File:Parameter view of commercial firmware.png|thumb|Parameter view of commercial firmware]]

===openinverter style charger firmware===
In addition to the open source firmware there is also an openinverter style firmware. It adds advanced features:
*Support for the standard open inverter web interface
*Parameter handling as known from the inverter firmware (see picture)
*Spot value handling like inverter including plotting, gauges, and logging
*Over the air update like inverter
*DC current control
* CAN control as described above
The firmware requires the board to be flashed with [https://github.com/jsphuebner/tumanako-inverter-fw-bootloader/releases stm32_loader.hex]. An Olimex MOD-ESP8266 must be programmed with the [https://github.com/jsphuebner/esp8266-web-interface openinverter web interface]. See [[Olimex MOD-WIFI-ESP8266]] and [https://openinverter.org/forum/viewtopic.php?f=5&t=8 this forum thread] for flashing instructions. With that done, future updates will happen via the web interface.

The firmware will soon be fully published and is only available via patreon for now: https://www.patreon.com/openinverter

====Connecting to the Web interface====
Depending on the version of your Olimex wifi dongle they are "open" or you need a password to connect.

By default you can connect to the network (Access Point) and browse to: '''192.168.4.1'''

By default all charger kits will have '''SSID''' : charger '''PASSWORD''' : charger123

''Note: Its recommend that you change it. Nobody wants to drive and have some joker with a phone finding this information and accessing your charger.''

'''Missing IC4 Chip'''

According to [https://openinverter.org/forum/viewtopic.php?p=43750&hilit=ic4#p43750 this forum post], IC4 used to be populated with a USB to serial FTDI chip. However, on the latest boards, all settings are configured via wifi so it is no longer needed.
[[File:Gen2ChargerBoard.jpg|alt=Image of Tesla Gen2 charger board with missing IC4 chip|thumb|Tesla Gen2 charger board with missing IC4 chip]]

====Registration====
This step is no longer needed as the firmware will soon be published. It is already available on patreon: https://www.patreon.com/openinverter

If you bought a fully assembled V5aB3 board from the EVBMW webshop you can skip this step.

=== Latest Software for V5 boards and later ===
[[Tesla Model S/Tesla Gen23 V5 Software]]

==Additional Resources==

Videos by Damien Maguire showing internals of the charger, CAN IDs, wiring, and development of the board:

[https://www.youtube.com/watch?v=LqJ7HhS65po The Tesla Project : 10 Kw Gen 2 Charger]

[https://www.youtube.com/watch?v=ULadBnl7wgM The Tesla Project : Charger Progress]

[https://www.youtube.com/watch?v=mOIgp3QFg78 The Tesla Project : 10kW Charger Charging]

[https://www.youtube.com/watch?v=BG4kYsoHe54 The Tesla Project : More Charger Hacking]

[https://www.youtube.com/watch?v=bPLqXCiArVM The Tesla Project : Charger 10kw Run]

A 15 min intro from a user perspective: https://www.youtube.com/watch?v=ibtr6v1k0cA

==Common Issues==

*The Tesla chargers are very sensitive to grounding. The case MUST be connected to vehicle 12v ground AND evse earth/ground when charging. [https://openinverter.org/forum/viewtopic.php?p=3890#p3890]
*With V5aB2, If you do NOT use the external CAN bus or are not properly terminated, '''remember to close the solder jumper''' next to R1 under the WiFi module. When in doubt, check the resistance of the CAN bus with all devices off. It should be 60 ohms ideally. If you are not using the external CAN then it should be 120 ohms.
*People had problems with unreliable connectivity between ESP8266 & the charger board [https://openinverter.org/wiki/Olimex_MOD-WIFI-ESP8266#Common_Issues]
*Firmware '''1.09''' and '''1.10''' can lose the CAN map, making the logic board go silent, reset instructions here: [https://openinverter.org/forum/viewtopic.php?p=40617&sid=e2369fea2b502a419f55e5aac10fe169#p40617]
*If a module within the charger is enabled (and all three are enabled by default) then it '''MUST''' see AC and DC voltage when charging starts. If it does not then no current will flow on any module. So, triple check your wiring before starting. It can be easy to mix up the line and neutral wires of the AC input. This will not blow up anything but it won't work either. Mixing up the DC wires is a recipe for a bad time.
*Some chargers are just raised wrong. As covered above, for reasons we don't know, some modules will simply refuse to work properly. Most often this will happen to chargers that were previously used in super charger stations but it can happen to chargers that were pulled from Model S cars as well. There is not yet any known fix for this. If it happens the only current solution is a different charger or you live with slow charging.
*Did you set the D1 enable pin to be high (+12v?) It must be high in '''ANY''' mode in order for charging to start. It is OK to tie it to the +12 incoming power if you are using something like Type2 where charging is controlled by the proximity and control pilot signals.

==Errata==
Charger Dimensions: 500x300x100mm

More specific dimensions and CAD info here: https://openinverter.org/forum/viewtopic.php?p=3641#p3641CAD

==Notes==
[[Category:OEM]]
[[Category:Tesla]]
[[Category:Charger]]

<references />

Tesla Model S/X GEN2 Charger

2024-10-29T18:21:17Z

Nubster: /* Missing IC4 Chip Explanation */

==Overview==
[[File:Gen2.jpg|thumb|tesla gen2 ac charger]]
[[File:Tesla gen2 xray.png|thumb|Tesla Gen2 X-Ray]]

The Tesla GEN2 on-board charger (OBC) is a single/three phase 10kW AC charger that was fitted in the Model S from approx. Oct2013<ref>https://teslamotorsclub.com/tmc/posts/6560948/</ref> until it was replaced in the 2016 'facelift' model with GEN3. It was the first Tesla OBC capable of fully utilizing external 3-phase AC; [[Tesla Model S GEN1 Charger|previous Tesla OBCs]] lacked the external wiring for three phases.

One or two GEN2 chargers are installed beneath the rear seats in the Model S for AC charging.

The charger is made up of three 3.3 kw modules, each sitting on a liquid cooling plate. This assembly enables both single and multi phase AC charging.

==Important Considerations==

===Output Voltage Range===
{| class="wikitable" style="background-color:#ffffcc;" cellpadding="10"
|'''HEED DAMIEN'S WARNING:'''<ref>https://openinverter.org/forum/viewtopic.php?p=9994#p9994</ref>
"[https://openinverter.org/forum/viewtopic.php?f=10&t=78&p=9994#p9994 Running a Tesla charger at much under 200v dc will cause it to explode. Yes I know the label says 50 to 450v but it lies. Yes I blew one up discovering this.]"
|}

===Supported Tesla Part Numbers (TPN)===
It has been found that early revision units will not work with the OI control boards.<ref>https://openinverter.org/forum/viewtopic.php?t=932</ref>

TPNs to avoid:

*1014963-05-B and 1014963-05-C

TPNs tested and known good:

*1014963-00-C/E/F/J/K/L
**1014963-00-C <ref>https://openinverter.org/forum/viewtopic.php?p=34710#p34710 and also by Lars on June 25th 2024</ref>
**1014963-00-G is likely also good, just wasn't mentioned by name in the referenced thread

=== Supported Software Revisions ===
At this time, it is not known why but it appears that some firmware revisions of this charger will have problems with maintaining a steady charge. Symptoms of this can be either surging (current goes up, drops to near zero, then surges back) or modules coming online singly followed by all modules going offline, repeat forever. In either case, charge power will be limited. We do not yet know what, exactly, is causing this. However, it is confirmed that swapping charger units but keeping the OI control board can produce working results.

===Cooling===
The direction of flow in the cooling plate does not seem to matter.<ref>https://openinverter.org/forum/viewtopic.php?p=2030#p2030</ref> The charger should likely be on the same cooling loop as the batteries themselves. This coolant loop should be separate from the loop with the motor and inverter (they get far too hot.) Limited testing (esp 110V, 1kw) can be done without the coolant lines hooked up. However, it would be unwise to attempt 10kw charging for any length of time without liquid cooling.

==Replacement Control Boards==
Replacement control board https://github.com/damienmaguire/Tesla-Charger

v5 kit: https://www.evbmw.com/index.php/evbmw-webshop/tesla-boards/tesla-gen-2-charger-logic-board-kit

v5 partially built board: https://www.evbmw.com/index.php/evbmw-webshop/tesla-boards/tesla-gen-2-charger-logic-board-partially-built

github: https://github.com/damienmaguire/Tesla-Charger

=== Charger Connections ===
[[File:Tesla Charger Logic connections.jpg|none|thumb|607x607px|
{| class="wikitable"
!A1
!A2
!A3
!A4
!A5
!
!B1
!B2
!B3
!B4
! B5
!B6
|-
|OUT2 - AC present
|
|D1 - enable
|
|
|
|12V supply
|
|
|CANH
|Control Pilot
|
|-
!A6
!A7
! A8
!A9
!A10
!
!B7
!B8
!B9
!B10
!B11
!B12
|-
|OUT1 - HV enable
|
|
|
|D2 - 3p
|
| GND
|
|
|CANL
|Proximity
|
|}
The outputs will not output 12v, they are low side switches. If you require a 12v ac present signal then use a relay with its coil switched from the relevant pin. [https://raw.githubusercontent.com/damienmaguire/Tesla-Charger/master/V5/Charger_Gen2_V5aB3%20-%20Schematic.pdf wiring diagram][[File:AC DC Connections.jpg|left|thumb|600x600px]]]]

====Connector part numbers====
AC and DC power connections (Molex Sabre series):

*housing: 044441-2006
*pins: 043375-3001 (18-20AWG), 043375-0001 (14-16AWG)

Logic connectors (Molex MX150L series):

*housing: 10-way 19418-0014, 12-way 19418-0026
*pins: 33012-2002 (18-20AWG), 33012-2001 (14-16AWG)

=== Replacement board connectors ===
If you can desolder 24 pin SMD connector off of the OEM control board otherwise to order 24 pin connector from Mouser P/N is:

* SM24B-CPTK-1A-TB(L)

The 30 pin connector is very difficult to desolder and resolder. Replacement P/N is:

* IPS1-115-01-S-D-PL, SAMTEC - IPS1-115-01-S-D-PL - SOCKET, 2.54MM, 2X15WAY

===Programming===
You'll need a ST-LINK/V2 smt32 programmer. Unofficial ones are cheaply available from amazon and ebay.

*ST-LINK programming utility: https://www.st.com/en/development-tools/stsw-link004.html
* stm32_loader.hex https://openinverter.org/forum/viewtopic.php?f=7&t=1119
'''Two options:'''
#Charger_gen2_v5.hex https://github.com/damienmaguire/Tesla-Charger/tree/master/V5/Software/Binary
#openinverter style firmware https://openinverter.org/forum/viewtopic.php?t=1323 (only available via patreon for next few weeks)

Click "Target --> Connect" from top menu. You want to see the screen get filled with a data dump of symbols. In the upper right of the screen you can see it identified the device.

In the main viewing window are multiple tabs, click the "Binary File" tab to select it.

This will ask to open a file, you choose: "stm32_loader.hex" from openinverter.org, download ahead of time. This will change what shows up in the viewing window.

Click "Target --> Program and Verify" from the top menu. This pops up a window, and you can probably just click "Start" on that window. This programs the STM32 chip with the stm32_loader.hex file.

The STM32 on your v5 gen2 Tesla charger Board can now load other files.

You can close the stm32_loader.hex tab, and go back to the "Binary File" tab, which will ask to open another file.

You choose: "Charger_Gen2_v5.hex"

Same as last time, click "Target --> Program and Verify" from the top menu. And click Start.

The STM32 on your v5 gen2 Tesla charger Board now also has the software to run.

You are now done with the ST-Link USB dongle, it's no longer needed.

Future updates can be done via WiFi. (must have esp8266 WiFi module programed https://openinverter.org/forum/viewtopic.php?f=5&t=8 )

=== External CAN bus===
[[File:Gen2 Charger V5aB2 logic board.jpg|thumb|Gen2 Charger V5aB2 logic board with CAN wired to external pins]]
The V5aB2 version of the board has no connection to the external CAN bus (V5aB3 has) but you can add it with two bodge wires as shown in the picture. You will find CANH and CANL on the 3 pin header underneath the WiFi module. Route them over to CONN6 as shown. CONN2.1 (CANH) is connected to CONN6.24, CONN2.2 (CANL) to CONN6.26.

Revision V5aB3 does not need this modification. On Revision V5aB3 you '''MUST''' close the solder jumper unless your charger is on an already terminated bus (that is, if the bus already has 2 termination resistors, one on each end, and measures 60 ohms with all devices powered off). If you do not use the external CAN, terminate the bus. If you have only two devices on the bus, terminate the bus. If you aren't sure, double check. '''Bus termination is important.'''

If you attach to the external CAN bus, be aware that all internal CAN traffic is also seen on the external CAN bus. The following IDs are already used and mustn't used by any other device on the bus:

207, 209, 20b, 217, 219, 21b, 227, 229, 22b, 237, 239, 23b, 247, 249, 24b, 327, 329, 32b, 347, 349, 34b, 357, 359, 35b, 367, 368, 369, 36b, 377, 379, 37b, 537, 539, 53b, 717, 719, 71b.

====Functionality of external CAN bus====
With the CAN bus now available externally you can remote control your charger via CAN and also receive some values from it. The mapping is similar to the CHAdeMO CAN protocol. The feature is only available in the commercial firmware.
{| class="wikitable"
|+Charger CAN protocol - up to version 1.06.R
!ID
!Direction
!Byte 0
! Byte 1
!Byte 2
!Byte 3
!Byte 4
! Byte 5
! Byte 6
!Byte 7
|-
|0x102
|Receive by charger
|
|DC voltage limit MSB
|DC voltage limit LSB
| DC current set point
|==1 enable charging
|SoC
|
|
|-
|0x108
|Transmit by charger
|Version=0
|Max DC voltage MSB
| Max DC voltage LSB
|Max DC current
|
|
|
|
|-
|0x109
|Transmit by charger
|Version=0
|DC voltage MSB
|DC voltage LSB
|DC current
|''0 when off, 5 when charging''

|
|
|
|}
Example: transmit "0x102 # 0 0x1 0x86 0x14 0x1 50 0 0" to enable charging up to a voltage of 390V and a DC current of 20A, report SoC of 50%

{| class="wikitable"
|+Charger CAN protocol - after version 1.06.R
!ID
!Direction
!Byte 0
!Byte 1
!Byte 2
!Byte 3
!Byte 4
!Byte 5
!Byte 6
!Byte 7
|-
| 0x102
|Receive by charger
|
|DC voltage limit MSB
|DC voltage limit LSB
|DC current set point
|
|==1 enable charging
|SoC
|
|-
|0x108
|Transmit by charger
|Version=0
|Max DC voltage MSB
| Max DC voltage LSB
|Max DC current
|
|
|
|
|-
|0x109
| Transmit by charger
|Version=0
|DC voltage MSB
|DC voltage LSB
|DC current
|
|0 when off, 5 when charging
|
|
|}
LR: Personally I think the data for DC voltage limit is incorrect. The above states Motorola but only when I set all signals (so not only DC voltage limit as also the start bit count (sometimes) varies) to Intel it works for me.[[File:Parameter view of commercial firmware.png|thumb|Parameter view of commercial firmware]]

===openinverter style charger firmware===
In addition to the open source firmware there is also an openinverter style firmware. It adds advanced features:
*Support for the standard open inverter web interface
*Parameter handling as known from the inverter firmware (see picture)
*Spot value handling like inverter including plotting, gauges, and logging
*Over the air update like inverter
*DC current control
* CAN control as described above
The firmware requires the board to be flashed with [https://github.com/jsphuebner/tumanako-inverter-fw-bootloader/releases stm32_loader.hex]. An Olimex MOD-ESP8266 must be programmed with the [https://github.com/jsphuebner/esp8266-web-interface openinverter web interface]. See [[Olimex MOD-WIFI-ESP8266]] and [https://openinverter.org/forum/viewtopic.php?f=5&t=8 this forum thread] for flashing instructions. With that done, future updates will happen via the web interface.

The firmware will soon be fully published and is only available via patreon for now: https://www.patreon.com/openinverter

====Connecting to the Web interface====
Depending on the version of your Olimex wifi dongle they are "open" or you need a password to connect.

By default you can connect to the network (Access Point) and browse to: '''192.168.4.1'''

By default all charger kits will have '''SSID''' : charger '''PASSWORD''' : charger123

''Note: Its recommend that you change it. Nobody wants to drive and have some joker with a phone finding this information and accessing your charger.''

'''Missing IC4 Chip'''

According to [https://openinverter.org/forum/viewtopic.php?p=43750&hilit=ic4#p43750 this forum post], IC4 used to be populated with a USB to serial FTDI chip. However, on the latest boards, all settings are configured via wifi so it is no longer needed.
[[File:Gen2ChargerBoard.jpg|alt=Image of Tesla Gen2 charger board with missing IC4 chip|thumb|Tesla Gen2 charger board with missing IC4 chip]]

====Registration====
This step is no longer needed as the firmware will soon be published. It is already available on patreon: https://www.patreon.com/openinverter

If you bought a fully assembled V5aB3 board from the EVBMW webshop you can skip this step.

=== Latest Software for V5 boards and later ===
[[Tesla Model S/Tesla Gen23 V5 Software]]

==Additional Resources==

Videos by Damien Maguire showing internals of the charger, CAN IDs, wiring, and development of the board:

[https://www.youtube.com/watch?v=LqJ7HhS65po The Tesla Project : 10 Kw Gen 2 Charger]

[https://www.youtube.com/watch?v=ULadBnl7wgM The Tesla Project : Charger Progress]

[https://www.youtube.com/watch?v=mOIgp3QFg78 The Tesla Project : 10kW Charger Charging]

[https://www.youtube.com/watch?v=BG4kYsoHe54 The Tesla Project : More Charger Hacking]

[https://www.youtube.com/watch?v=bPLqXCiArVM The Tesla Project : Charger 10kw Run]

A 15 min intro from a user perspective: https://www.youtube.com/watch?v=ibtr6v1k0cA

==Common Issues==

*The Tesla chargers are very sensitive to grounding. The case MUST be connected to vehicle 12v ground AND evse earth/ground when charging. [https://openinverter.org/forum/viewtopic.php?p=3890#p3890]
*With V5aB2, If you do NOT use the external CAN bus or are not properly terminated, '''remember to close the solder jumper''' next to R1 under the WiFi module. When in doubt, check the resistance of the CAN bus with all devices off. It should be 60 ohms ideally. If you are not using the external CAN then it should be 120 ohms.
*People had problems with unreliable connectivity between ESP8266 & the charger board [https://openinverter.org/wiki/Olimex_MOD-WIFI-ESP8266#Common_Issues]
*Firmware '''1.09''' and '''1.10''' can lose the CAN map, making the logic board go silent, reset instructions here: [https://openinverter.org/forum/viewtopic.php?p=40617&sid=e2369fea2b502a419f55e5aac10fe169#p40617]
*If a module within the charger is enabled (and all three are enabled by default) then it '''MUST''' see AC and DC voltage when charging starts. If it does not then no current will flow on any module. So, triple check your wiring before starting. It can be easy to mix up the line and neutral wires of the AC input. This will not blow up anything but it won't work either. Mixing up the DC wires is a recipe for a bad time.
*Some chargers are just raised wrong. As covered above, for reasons we don't know, some modules will simply refuse to work properly. Most often this will happen to chargers that were previously used in super charger stations but it can happen to chargers that were pulled from Model S cars as well. There is not yet any known fix for this. If it happens the only current solution is a different charger or you live with slow charging.
*Did you set the D1 enable pin to be high (+12v?) It must be high in '''ANY''' mode in order for charging to start. It is OK to tie it to the +12 incoming power if you are using something like Type2 where charging is controlled by the proximity and control pilot signals.

==Errata==
Charger Dimensions: 500x300x100mm

More specific dimensions and CAD info here: https://openinverter.org/forum/viewtopic.php?p=3641#p3641CAD

==Notes==
[[Category:OEM]]
[[Category:Tesla]]
[[Category:Charger]]

<references />

File:Gen2ChargerBoard.jpg

2024-10-29T18:17:09Z

Nubster:

Gen2 Charger board with missing IC4 chip

Tesla Model S/X Large Drive Unit ("LDU")

2024-10-20T21:10:01Z

Nubster: /* Encoder Plug */ pin mappings

== Overview ==
[[File:Tesla LDU.jpg|alt=Tesla LDU|thumb|Tesla Large Drive Unit]]
The Tesla Model S/X Large Drive Unit (LDU) was the first drive unit produced by Tesla dating back to the launch of the Model S in 2012. Applications include RWD Model S & X, as well as performance AWD S & X - in both cases serving as the rear drive unit.

=== Specs: ===

* Weight: 291 lbs (132 kg)
* Input Voltage: 240-404V DC
* Power: 335 kW (~450HP) to 475 kW (~636 HP) depending on configuration
* Torque: 450 Nm (~332 ft/lb) to 650 Nm (~480 ft/lb) depending on configuration
* Max RPM: 18,000
* Gear ratio: 9.73:1

== Connections ==

=== Overview ===
[[File:LDU connection diagram.png|thumb|489x489px|LDU connection diagram|none]][[File:HV wiring.jpg|thumb|487x487px|HV wiring with precharge and main contactors|none]]
=== Low-Voltage ===

==== Main I/O Plug ====
The main low-voltage connector is a 23-pin socket from the TE AMPSEAL family:

* Housing (F): 770680-1
* Pins (F): 770520-1 (20-16 AWG)

===== Connector Mapping/Pinout =====
{| class="wikitable"
|'''PIN NUMBER'''
|'''OEM'''
|'''OPEN SOURCE'''
|-
|'''1'''
|IGN +12V
|IGN +12V
|-
|'''2'''
|BRAKE ON N.O.
|BRAKE ON
|-
|'''3'''
|BRAKE OFF N.C.
|PRECHARGE RELAY
|-
|'''4'''
|CAN HIGH
|CAN HIGH
|-
|'''5'''
|CAN LOW
|CAN LOW
|-
|'''6'''
|CHG PROXIMITY
|MAIN CONTACTOR
|-
|'''7'''
|HVIL IN
|FORWARD
|-
|'''8'''
|HVIL OUT
|REVERSE
|-
|'''9'''
|ENC +5V
|ENC +5V
|-
|'''10'''
|ENC A
|ENC A
|-
|'''11'''
|GND
|GND
|-
|'''12'''
|ACCEL 1 +5V
|ACCEL 5V
|-
|'''13'''
|ACCEL 1
|ACCEL INPUT
|-
|'''14'''
|ACCEL 2
|BRAKE TRANSDUCER
|-
|'''15'''
|ACCEL 1 GND
|ACCEL GND
|-
|'''16'''
|ENC B
|ENC B
|-
|'''17'''
|ENC GND
|ENC GND
|-
|'''18'''
|ENC SHIELD
|ENC SHIELD
|-
|'''19'''
|CAN HIGH OUT
|
|-
|'''20'''
|CAN LOW OUT
|
|-
|'''21'''
|ACCEL 2 +5V
|CRUISE IN
|-
|'''22'''
|ACCEL 2 GND
|GND
|-
|'''23'''
|12V ALWAYS T30
|START
|}

==== Encoder Plug ====
A smaller 4 pin LV connector is responsible for the encoder signals. The plug is TE 444046-1; this part is EoL from TE, however the connector is [https://www.aliexpress.com/w/wholesale-444046%2525252d1.html widely available on Aliexpress].

Per the [https://openinverter.org/forum/viewtopic.php?p=1026#p1026 Tesla Large Drive Unit Support Thread] :

* Pin 1 of the Encoder connector to Pin 17 of the 23way ampseal main connector
* Pin 2 of the Encoder connector to Pin 16 of the 23way ampseal main connector
* Pin 3 of the Encoder connector to Pin 10 of the 23way ampseal main connector
* Pin 4 of the Encoder connector to Pin 9 of the 23way ampseal main connector

'''Contactors'''

Please note that the contactors you purchase *may* have polarity associated with them for the low voltage control signal. If you have problems related to the pre-charge circuit working, or contactors behaving as not expected, check this!

=== High-Voltage ===
The OEM LDU HV cables' insulation OD is ~.680" (17.3mm) (verified for the "early" Model S units). The HV cables are EMC shielded, and use proprietary EMC cable glands which are not available separately. Fellten supplies custom aftermarket cable glands to fit the LDU's case and aftermarket 70mm<sup>2</sup> shielded cabling<ref>https://shop.fellten.com/shop/lduhvcg-ldu-high-voltage-cable-gland-12803#attr=</ref>. The early Model S LDU cables are ~44" (1120mm) in length. One part No. for the cables set is 1004872-00-B.
[[File:Tesla Model S LDU HV Cables 1004872-00-B 05b.jpg|alt=Tesla Model S LDU HV Cables' proprietary gland connector.|thumb|450x450px|Tesla Model S LDU HV Cables' proprietary gland connector.]]

[[File:Tesla Model S LDU HV Cables 1004872-00-B 03-1b.png|alt=Tesla Model S LDU HV Cables' proprietary gland connector.|center|thumb|Tesla Model S LDU HV Cables' proprietary gland connector.]]
The OD of the casting where the external o-ring is located is ~1.030" (26.2mm). The OEM gland nuts are plated and are often found in a corroded state.

== Tesla Large Drive Unit Logic Board ==
An openinverter based control board has been made available by Damien Maguire. A "community edition" (i.e. mostly complete) version is available [https://openinverter.org/shop/index.php?route=product/product&product_id=64 here on the OI webshop], or you can have your own made from info contained in [https://github.com/damienmaguire/Tesla-Drive-Unit Damien's LDU github repo].

This board replaces the original board that comes with the OEM Tesla drive train. As opposed to the latter, this board lets you use the drive train in the first place and allows you to fine-tune driving behaviour with the usual set of openinverter parameters. It does not restrict you in power output or regen input.

You can fully control the board via CAN or via a set of digital and analog inputs.

=== Application Info ===
If you buy the board from the openinverter shop it comes programmed with a recent software version. Please check [https://github.com/jsphuebner/stm32-sine/releases github] for recent software releases. In addition the board comes with a set of parameters appropriate to run the Tesla LDU. So it will work out of the box. Parameters that must not be changed are hidden to eliminate sources of error.

You will need to solder the supplied connectors to the board. The drive unit connectors will plug right in.

To test run your drive unit, supply the board with 12V and GND on the Ampseal connector. Also supply 12V „Forward“ to select forward direction.

Supply inverter with some high voltage. For first tests it is recommended to put a large resistor/heating element/kettle in series.

You can start in manual mode using the button on the web interface and enter like 1Hz for „Fslipspnt“ and some value between 10-50 for „ampnom“ to see if the motor spins up. Be careful because manual mode does not enforce a motor speed limit! However, „Fslipspnt“ sets the base speed requested of the motor. Setting it to 1Hz will spin the motor very slowly. Setting it to 5, 10, or 15Hz will spin it progressively faster. For any given speed you will need to experiment with „ampnom“ to find a happy place where enough current is allowed to flow but not too much. Finding a good set of values should make your motor spin reasonably smoothly. Also check the „Boost“ as it may require an increased value of 5000-10000.

You may also set parameter „udcsw“ and „udcmin“ to 0 and start drive mode by pulsing 12V on „Start“. Then connect a pot between 5V, GND and „Pot“ (wiper). This will also spin the motor AND enforce a speed limit.

By default the inverter is controlled as above - by using digital I/O and directly connecting an accelerator pedal. However, it is also possible to control it directly over CAN: [[CAN communication]]

CAN control could be used to control the inverter via an external VCU such as the Zombie (not yet supported).

==== Additional Resources ====
[https://openinverter.org/parameters/view.html?id=16 Parameters]

[[Tesla Setup FAQ]]

== Tuning and Parameters ==
There are several tuning threads and sets of shared parameters on the Open Inverter Forum. The two most useful collections are: [https://openinverter.org/forum/viewtopic.php?t=195&hilit=parameters Original Parameter Sharing Thread] and the [https://openinverter.org/forum/viewtopic.php?t=126 Tuning Discussion Thread].

The tuning guide [https://openinverter.org/forum/viewtopic.php?p=15385#p15385 here] has lots of useful information regarding the impact of various parameters on the LDU.

The main Open Inverter parameter definition page is located [[Parameters|here]].

== Failure Modes ==

=== Encoder Issues ===
It is not uncommon to have issues with the encoder on these drive units. The encoder is connected via a 4 wire cable from the 23 pin external connector of the drive unit to the encoder which is situated on the opposite side of the drive unit. The biggest sign of encoder problems is the motor "bucking" back and forth and not wanting to spin properly in the requested direction. It may spin the direction you've asked for but roughly and with great trouble. This situation needs to be corrected. There are a number of things that could be wrong:

# The wires may be broken. You should attempt a continuity check of each of the wires.
# The encoder signals may be backward. There are two channels - A and B. They must be presented to the inverter in the proper order. If this is in doubt, try swapping them.
# One of the encoder signals may be missing. As above, there should always be two channels. They're "quadrature" which means that they fire 90 degrees apart.

To check the encoder signals you should have either a logic analyzer or an oscilloscope. Both come in a wide range of prices. The encoder signal is not particularly fast, especially when the motor is not spinning that fast. As such, even cheap test equipment can be adequate. You may find that there is no particularly good place to connect to in order to read the encoder signals. But, there does exist a reasonable place - right at the 20 pin connector on the LDU board where the 23 pin external connector's wires are routed. If your logic analyzer or oscilloscope has little grabber adapters you can do something like in this picture:
[[File:ClipsOnPins-LDUEncoder.jpg|frame]]

The pins on this connector are numbered starting with 1 at the far right and going more positive toward the left until you get to pin 20.
{| class="wikitable"
|+
!Pin Number
!Function
|-
|5
|Encoder 5V Source
|-
|6
|Encoder A Channel
|-
|7
|Encoder B Channel
|-
|8
|Encoder Ground
|}

So, in the picture, channel 0 is connected to encoder 5v (to monitor that voltage is properly there), channel 1 is connected to the A channel of the encoder, channel 2 is connected to the B encoder channel, and scope ground is connected to the encoder ground wire. This allows for monitoring all of the relevant signals. But, keep in mind not to short any pins while doing this. Very fine probes will be needed and extreme caution not to clip two pins together. The clips/grabbers in this picture are from a Saleae Logic Pro 8. This is *NOT* your cheapest option for monitoring encoder signals but does work very well. It also doubles as a 50Mhz oscilloscope which can be handy. Cheaper options (including knock offs of Saleae Logic) do exist.

Here is a picture of what it may look like when one encoder signal is missing:
[[File:Logic Encoder1.png|center|frame|Note how Channel 1 shows an encoder signal but Channel 2 looks completely flat. This should not occur. If one is showing a signal, so should the other.]]

Another good way to check the encoder is to use the steps to enter manual mode but do not set "Fslipspnt" nor "ampnom". You need to not be in "Off" mode. In Off mode the speed and turns values do not update in the spot values. But, in manual mode they do. So, enter manual mode without asking for any speed, then turn the motor. With the motor spinning you should see some position feedback in the form of a non-zero speed value and the turns value should increment. If these things do not reliably occur then you may still be having encoder problems. If they do occur, still check to ensure that your A and B channels are the right way around.

=== Internal Coolant Leaks ===
The Tesla LDU is famous for springing a leak on the motor side. Right there at the inlet there is a seal to the motor shaft. It fails then coolant starts to seep into the motor itself. This rusts the hell out of the motor internally until so much sludge builds up that it looks like a mud pie. Obviously, that is less than ideal. One way to check for this sort of thing is to go to the motor side and remove the one bolt that holds the encoder into the motor housing. If the encoder is soaking wet inside or looks like there is a slurry of liquid poo in the motor then there is bad news.

I'm not sure if there is any good pathway from the motor leak to the inverter so they could be two separate issues. In fact, having taken one apart, I guess that's almost certainly the case. But, the inverter has coolant running to it as well.

Anyway, still check the encoder because that part is famous for leaking too and it ruins the motor.

== Other considerations ==
The motor itself will run as well in the reverse direction as in the forward direction. However if you are running the gearbox integrated with the drive unit in reverse you will want to replace the gearbox's oil pump with a reverse oil pump. These can be found on ZeroEV. [https://zero-ev.co.uk/product/tesla-large-drive-unit-replacement-reverse-drive-oil-pump/?v=3a52f3c22ed6]

[[Category:OEM]] [[Category:Tesla]] [[Category:Motor]] [[Category:Inverter]] [[Category:Gearbox]]
<references />

== CAD ==
An amazing-quality solid model of this drive unit has been [https://grabcad.com/library/tesla-rear-drive-unit-1 made available on GrabCAD] by Winston Jennings.

Tesla Model S/X Small Drive Unit ("SDU")

2023-11-27T06:43:32Z

Nubster: /* Resources */ corrected component name

== Overview ==
Tesla uses the Small Drive Unit (SDU) in dual-motor versions of the Model S/X. The Front SDU (FDU) is found in performance and non-performance dual-motor models, while the Rear SDU (RDSU) is only found in non-performance dual motor models.

== Wiring ==
[[File:Drive Inverter Front Connector.png|thumb|Small Drive Unit ("SDU") Data Connector|alt=]]
=== Low Voltage Data Connector ===
[[File:Drive Inverter Front Connector Schematic.png|thumb|Small Front Drive Unit ("SDU") Data Schematic|alt=]]

==== '''Housing:''' ====
Molex MX150 33472-2002 (key “B”)

==== '''Pins:''' ====
22 AWG: Molex 33012-2003

18-20 AWG: Molex 33012-2002

14-16 AWG: Molex 33012-2001
=== High Voltage Power Connectors===
Although the connectors are known ([https://www.rosenberger.com/product/hpk/ Rosenberger HPK series]), they are not available through conventional vendors.

==Drop-in control board==
[[File:Tesla SDU controller connections.png|thumb|Tesla SDU drop-in board]]

This board replaces the original board that comes with the OEM Tesla drive train. As opposed to the latter this board lets you use the drive train in the first place and allows you to fine-tune driving behaviour with the usual set of openinverter parameters. It does not restrict you in power output or regen input.

You can fully control the board via CAN or via a set of digital and analog inputs.

===Resources===
[https://github.com/damienmaguire/Tesla-Front-Drive-Unit/blob/master/SDU_Wiring_Connections.pdf Wiring connections]

[https://github.com/damienmaguire/Tesla-Front-Drive-Unit/blob/master/FDU_Main_conn_pinout_V1.ods Pinout]

[https://openinverter.org/shop/index.php?route=product/product&product_id=62 Purchase in openinverter shop]

[https://openinverter.org/parameters/view.html?id=15 Parameters]

[[Setup FAQ]]

[https://www.thingiverse.com/thing:6230844 MX150 male header receptacle STL on Thingiverse]

===Application Info===
The board comes programmed with a recent software version. Please check [https://github.com/jsphuebner/stm32-sine/releases github] for recent software releases. In addition the board comes with a set of parameters appropriate to run the Tesla SDU. So it will work out of the box. Parameters that must not be changed are hidden to eliminate sources of error.

{| class="wikitable" style="background-color:#ffffcc;" cellpadding="10"
|'''It is essential that the tripmode parameter is set to 1 "DcSwOn"'''. Also do not use a low value fuse while testing. On over current trips some energy is still stored in the motor and it has nowhere to go if the contactor/fuse opens leading to immediate destruction of your inverter.
|}

You will need to solder the supplied connectors and the current sensors embedded into the inverter assembly to the board, see [https://youtu.be/VVSRzmP-fRw this video].

To test run your drive unit, supply the board with 12V and GND on Conn6.13 and Conn6.19, respectively. Also supply 12V to Conn6.5 to select forward direction.

Supply inverter with some high voltage. For first tests it is recommended to put a large resistor/heating element/kettle in series.

You can start in manual mode using the button on the web interface and enter like 1Hz for „Fslipspnt“ and some value between 10-50 for „ampnom“ to see if the motor spins up. Be careful because manual mode does not enforce a motor speed limit!

You may also set parameter „udcsw“ and „udcmin“ to 0 and start drive mode by pulsing 12V on Conn6.9. Then connect a pot between Conn6.4, Conn6.7 and Conn6.8 (wiper). This will also spin the motor AND enforce a speed limit.

==Cooling ==

===Small Front Drive Unit (FDU)===
[[File:Tesla FDU cooling.jpg|none|thumb|Tesla FDU cooling]]

===Small Rear Drive Unit (SRDU)===
[[File:Tesla SRDU cooling.png|none|thumb|Tesla SRDU cooling]]
[[Category:OEM]]
[[Category:Tesla]]
[[Category:Motor]]
[[Category:Inverter]]

Tesla Model S/X Small Drive Unit ("SDU")

2023-09-23T17:58:08Z

Nubster: /* Resources */

== Overview ==
Tesla uses the Small Drive Unit (SDU) in dual-motor versions of the Model S/X. The Front SDU (FDU) is found in performance and non-performance dual-motor models, while the Rear SDU (RDSU) is only found in non-performance dual motor models.

== Wiring ==
[[File:Drive Inverter Front Connector.png|thumb|Small Drive Unit ("SDU") Data Connector|alt=]]
=== Low Voltage Data Connector ===
[[File:Drive Inverter Front Connector Schematic.png|thumb|Small Front Drive Unit ("SDU") Data Schematic|alt=]]

==== '''Housing:''' ====
Molex MX150 33472-2002 (key “B”)

==== '''Pins:''' ====
22 AWG: Molex 33012-2003

18-20 AWG: Molex 33012-2002

14-16 AWG: Molex 33012-2001
=== High Voltage Power Connectors===
Although the connectors are known ([https://www.rosenberger.com/product/hpk/ Rosenberger HPK series]), they are not available through conventional vendors.

==Drop-in control board==
[[File:Tesla SDU controller connections.png|thumb|Tesla SDU drop-in board]]

This board replaces the original board that comes with the OEM Tesla drive train. As opposed to the latter this board lets you use the drive train in the first place and allows you to fine-tune driving behaviour with the usual set of openinverter parameters. It does not restrict you in power output or regen input.

You can fully control the board via CAN or via a set of digital and analog inputs.

===Resources===
[https://github.com/damienmaguire/Tesla-Front-Drive-Unit/blob/master/SDU_Wiring_Connections.pdf Wiring connections]

[https://github.com/damienmaguire/Tesla-Front-Drive-Unit/blob/master/FDU_Main_conn_pinout_V1.ods Pinout]

[https://openinverter.org/shop/index.php?route=product/product&product_id=62 Purchase in openinverter shop]

[https://openinverter.org/parameters/view.html?id=15 Parameters]

[[Setup FAQ]]

[https://www.thingiverse.com/thing:6230844 MX150 female connector STL on Thingiverse]

===Application Info===
The board comes programmed with a recent software version. Please check [https://github.com/jsphuebner/stm32-sine/releases github] for recent software releases. In addition the board comes with a set of parameters appropriate to run the Tesla SDU. So it will work out of the box. Parameters that must not be changed are hidden to eliminate sources of error.

{| class="wikitable" style="background-color:#ffffcc;" cellpadding="10"
|'''It is essential that the tripmode parameter is set to 1 "DcSwOn"'''. Also do not use a low value fuse while testing. On over current trips some energy is still stored in the motor and it has nowhere to go if the contactor/fuse opens leading to immediate destruction of your inverter.
|}

You will need to solder the supplied connectors and the current sensors embedded into the inverter assembly to the board, see [https://youtu.be/VVSRzmP-fRw this video].

To test run your drive unit, supply the board with 12V and GND on Conn6.13 and Conn6.19, respectively. Also supply 12V to Conn6.5 to select forward direction.

Supply inverter with some high voltage. For first tests it is recommended to put a large resistor/heating element/kettle in series.

You can start in manual mode using the button on the web interface and enter like 1Hz for „Fslipspnt“ and some value between 10-50 for „ampnom“ to see if the motor spins up. Be careful because manual mode does not enforce a motor speed limit!

You may also set parameter „udcsw“ and „udcmin“ to 0 and start drive mode by pulsing 12V on Conn6.9. Then connect a pot between Conn6.4, Conn6.7 and Conn6.8 (wiper). This will also spin the motor AND enforce a speed limit.

==Cooling ==

===Small Front Drive Unit (FDU)===
[[File:Tesla FDU cooling.jpg|none|thumb|Tesla FDU cooling]]

===Small Rear Drive Unit (SRDU)===
[[File:Tesla SRDU cooling.png|none|thumb|Tesla SRDU cooling]]
[[Category:OEM]]
[[Category:Tesla]]
[[Category:Motor]]
[[Category:Inverter]]