The information on the DIYElectricCar link https://www.diyelectriccar.com/threads/ ... ox.193729/ could be helpful.

I had a long running problem with a Tesla charger, where it failed after a few second when I tried to run all three modules. However, I could only get any 1 of the 3 modules running at a time. It I tried to run all three again, all would fail. Then I got any 2 of the 3 to run. Once I improved the ...

Two sets of measurements 1) Main DCDC box 2) DCDC Box with connectors and coolant pipes
Tesla Gen 2 DCDC - From a 2015 Model S 70D
Give or take a few mm's :)

Main DCDC Box
Height 67mm
Length 260mm
Width 190 mm

DCDC Box with Connectors/Coolant pipes
Height 80mm (coolant pipe rises above the box by ...

I've posted some prototype and demo code to my github to use the Bender ISO165C unit.

https://github.com/DrJeffCooke/IsolationMonitorBender

The unit measures the isolation of an EV system (effectiveness in kOhms of the insulation) and also two high voltage readings. It then reports these in CAN ...

So, all along it was the mess of your testing setup?


Yep, sure looks like it - one of the downsides of learning as you go. Of course trying to 'debug' something like this is a bit of a crap shoot... is it the charger version (couldn't get a clear steer on whether anyone else had my version ...

PROGRESS!!! 2/3, but still better :)

That is good news :D

Does your EVSE have the ability to generate a pilot signal below 40A? Some have configuration switches for installations that can't support that much current. Would be interesting to know whether the system behaves the same when ...

Correctly grounding the charger case, 12V ground and EVSE/AC ground to the same point is curcial for this all to work.

All EVSE signals are ground referenced, also the modulels have leakage detections and earthing checks.


SUCCESS!! All 3 modules Charging.

Some additional changes this morning ...

PROGRESS!!! 2/3, but still better :)

Thanks guys for the help - finally some progress that points towards a cause !!!

I replaced both PSUs (feeding the 12v/GND for the Charger AND 12v/GND to the Contactors controller) with a single car battery, feed through a switch and a 15A fuse. This allows 2 ...

So I stuck an oscilloscope on the control pilot line from the EVSE (with a reference ground back to the GND on the charger). When the EVSE was not activated the amplitude of the square wave was 20V (??? expected 12V). When the EVSE was activated the square wave amplitude fell to 17V. I only use ...

Help needed - I'm open to any ideas no matter how wild - regarding these symptoms.


I would drop the evse and test it in manual mode, connected directly to mains without contactors.
Then you can try without ground from the mains (if mains ground is a problem)

This is good advice ...

Hi Kevin,

Thanks for the ideas... To get started on chasing things down, I drew up a diagram of my HV and power connections for the desktop charger testing.

Charger HV and Power Connections.PNG

1. Charger Case Earth
- The 'primary' earth for the charger case would be via the case on the HVJB ...

Help needed - I'm open to any ideas no matter how wild - regarding these symptoms.
can get charging running on 1 module, any module, but not 2 or 3 modules at the same time
when 2 or 3 modules attempted, it resets on the 'Activate' command
no cooling system is fitted yet
tried two chargers ...

Chasing down the "Gen2 US EVSE SinglePhase 16Amp limited - Only one module will activate" problem.

Data Points for my setup
1) Modules are measuring only 16Amp available from the EVSE
2) EVSE duty cycle is 67% or 40Amps
3) Only 1 module will run, any of the three modules, but only 1 at a time ...

When building out the OpenSource board for the Tesla Charger, what is the process for uploading the most recent firmware to the board? I'd happily accept someone pointing me in the right direction for video or written walk thru. Thanks in advance.


Here's how I have it set up... (I can't ...

When I try to run two modules (which doesn't work - they just reset), I'm seeing from frames 0x207 and 0x209 'line 2 voltage' 120V and 'input voltage' 240V for both modules. This is consistent all through the test (i.e. enabled modules and resetting). On the DC side from frames 0x227 and 0x229 I'm ...

Hi Tom,

This sounds very similar to the symptoms I've been getting. I've got the charger connected to my EVSE on 220v SInglePhase. I can only get one module to function (any module works, but only one) at a time. If I enable 2 or 3 modules they just keep resetting. If I enable 1 module it quite ...

Is there guidance available on how to hook up Single Phase US power to the charger (I'm connecting via a HVJB), and any special provisions for grounding?

My chargers are models 1014963-00-K and 1014963-00-J. I can only get one of the three modules to charge (any module, just only 1 at a time). Both chargers behave exactly the same. I suspect temperatures (that firmware is regulating modules operating based on temp readings) but haven't gotten to ...

Due to way too many hours spent on airplanes today (about 22hrs in total) I did lots of examining and reasoning about how the charger internal CAN traffic scheme might be set up. The scheme (built up from examining the logs and internals of the Gen2Tesla charger software from Damien and Tom DeBree ...

What I mean is if you power off everything and measure resistance between canh and canl on the internal network what do you read? Just trying to gauge if Tesla have done something weird.


Easy to do, but it'll have to wait until I'm back in the US. Next three weeks I'm working in Australia.

I ...

Jack Bauer wrote: ↑Fri Jun 14, 2019 4:57 pm Jeff have you measured the can resistance?

Umm, not sure what you mean? The CAN transceiver didn't apply any additional resistance to the lines (60 Ohm or 120 Ohm), I just connected the internal CAN network pins on the control board to my transceiver.

Jeff

I finally got two CAN logs, 1 module charging and 2 modules failing to charge :) I tried 3 different CAN transceivers before I got it working - conclusion CAN is quirky.

Two logs attached...
1) mod1 good run 2.txt [one module activated and charging successfully from 240v EVSE, current set at 10amps ...

More data...

The oscilloscope confirmed the CAN on the internal charger network, but I was unable to read any CAN (possibly some odd incompatibility between my CAN reader and the internal network - it reads other CAN sources fine, just not this one). I read frames yesterday - but now I suspect that ...

A capture and a new symptom in the process...

I attached a CAN receiver to the pins on Damien's charger controller. I was able to capture some CAN frames while activating 1 module for charging. The new symptom is that the 1 module does not start charging (???). It exhibits the symptoms that I saw ...

Jeff could you do a can capture of both situations on the internal can network and send to me. There is a 3 pin header on the top left of the logic board to give access to internal can.


I'll get this done. I've captured from the internal pics before. My EVTV CANDue has died (becoming a habit ...