Tesla Charger Support Thread

[Jack Bauer]

A quick search on this very thread using the search term "IC4" shows that I have answered that question before :
viewtopic.php?p=43750&hilit=ic4#p43750
Sadly that important piece of information was not added to the wiki.

Regards wifi I have been having a hell of a time with these modules. 50% just dont program here on the bench for me and end up in the bin. It looks like even some of those that do program and test are failing in the field. I would advise reprogramming to see if it helps:
viewtopic.php?t=8
Working on a replacement module but will take time.

oh and just in case anyone missed it I'll shout : I WILL NOT RESPOND TO, OR PROVIDE SUPPORT VIA EMAIL OR PM!
In case this reason for that escapes people see this post.

[arber333]

Regards wifi I have been having a hell of a time with these modules. 50% just dont program here on the bench for me and end up in the bin. It looks like even some of those that do program and test are failing in the field. I would advise reprogramming to see if it helps:
viewtopic.php?t=8

I had the same issue with another Wifi module from you. I know about the issue and didnt frett much. Mostly now i use Wemos D1 mini module and make a simple wiring connector so i can connect it directly to any Olimex ready board. It is easier to program and seems to be more reliable.
I figured it also makes for a better range somewhat.

[Jack Bauer]

Great minds and all that. Just designing an adapter board. Had my fill of those olimex modules.

[RandallATX]

I finally got some time to work on my 944 Tesla project but I can't get more than ~120v coming out of my Gen 2 charger.

Here's my setup:
Gen2 charger with v5aB3 board
EVSE 32A 240v single phase external charger,
P85 Model S pack (all 16 modules) for ~400v.
On-board charger connected to the battery-side of the contactors.

The "Charging" light on the external charger is on when the charge port is connected to the car, and the 3 rails in the gen2 are each lit up with a single red led.
On the low voltage side of the Gen 2, I only have the following wires connected: CP, Proximity, +12v, Gnd, and Charge Enable connected. No CAN, as it seems like *every* component I bought is not compatible with any other component. stupid me.

I'm hoping someone can help me understand what I've screwed up to cause only ~120v to come out of the on-board unit.
EDIT: Running 1.06.R of the commercial firmware.

Here's my config:

[arber333]

I finally got some time to work on my 944 Tesla project but I can't get more than ~120v coming out of my Gen 2 charger.

I noticed your AC current limit is set to 20. I had some strange things happen with similar settingg. Can you correct it to 16?
Also you must connect HV battery for charger to work correctly.

[RandallATX]

I noticed your AC current limit is set to 20. I had some strange things happen with similar settingg. Can you correct it to 16?
Also you must connect HV battery for charger to work correctly.

I will try that and report back. Thanks for the heads up.

Also, I do have the charger hooked up to the full 16 model S modules

[RandallATX]

I noticed your AC current limit is set to 20. I had some strange things happen with similar settingg. Can you correct it to 16?
Also you must connect HV battery for charger to work correctly.

hot damn that did it. it also seems to be talking to the CAN quite well. my SOC shows 124% but there are worse problems. thank you.

[arber333]

hot damn that did it. it also seems to be talking to the CAN quite well. my SOC shows 124% but there are worse problems. thank you.

My pleasure .
How many kW did you get from it?

[RandallATX]

My pleasure .
How many kW did you get from it?

I have no idea...?

I didn't have cooling hooked up to the charger yet, so when the charger modules got to about 55c, I shut it down, but that brought me back up to 300v from 120v, so that was awesome. My statement is highly under-stated; I did a happy dance around the garage last night when I saw the charging voltage was an expected number, rather than a disappointing number.

I have tasks for hooking up cooling this weekend to get that charger fully automatic.

[arber333]

I have no idea...?

I didn't have cooling hooked up to the charger yet, so when the charger modules got to about 55c, I shut it down, but that brought me back up to 300v from 120v, so that was awesome. My statement is highly under-stated; I did a happy dance around the garage last night when I saw the charging voltage was an expected number, rather than a disappointing number.

I have tasks for hooking up cooling this weekend to get that charger fully automatic.

I noticed your charger reports HWlimit to 7A per module same as mine. This got me interested. Maybe some model chargers just have 13kW limit in firmware and there is nothing wrong with mine...

[arber333]

Hi

Can anyone confirm to me if it is OK to use all straight wires on Gen3 charger modules the way Damien shows in his video? If you actually used them like that for CAN lines for prolonged time and how is it working?
I can see on some of my equipment if i use straight lines for a bit of distance on CAN it actually works, but after some 30cm signal is lost if wires are not twisted.

tnx

[timbradley]

params (2).jsoncharger settings.JPGcharger lights.jpg

Have my new board installed and communicating through WiFi. Settings attached and photo of LEDs attached.

All modules are powering up, based on LEDs on each module.

Board LEDs are as shown, with upper LED (of two stacked amber LEDs) flashing (might appear solid in photo - it's not).

I can read battery voltage at DC connections on charger, but it is not outputting DC voltage (in other words, contactors are open but battery is not being charged).

Any suggestions?

Hi everyone, Quick update the controller board is powered on and communicating properly. Along with the charger powering on when 120v ac is applied. However the charger is still not outputting any Voltage. we have also tried this with another tesla charger and got the same results

Any suggestions?

[EV_Builder]

Charger type nr?
A can log available ?

[timbradley]

It is a Gen2 Tesla charger with an EVBMW board. Orion BMS. Even when we set it up in "bench test" mode (separate from BMS "control"), it behaves the same way.

We've tried our backup charger too. Same results. Board powers, charger modules light up, no DC voltage coming out. We are connected to 16 18650 that are currently sitting at about 349 volts.

It's almost like there is something in the board not allowing a charge to occur even after all interlocks are satisfied.

{
"idclim": {"unit":"A","value":19.00,"isparam":true,"minimum":0.00,"maximum":45.00,"default":45.00,"category":"Charger","i":0},
"iaclim": {"unit":"A","value":15.00,"isparam":true,"minimum":0.00,"maximum":72.00,"default":16.00,"category":"Charger","i":1},
"idcspnt": {"unit":"A","value":30.00,"isparam":true,"minimum":0.00,"maximum":45.00,"default":45.00,"category":"Charger","i":2},
"chargerena": {"unit":"1=Charger1, 2=Charger2, 4=Charger3","value":2.00,"isparam":true,"minimum":1.00,"maximum":7.00,"default":7.00,"category":"Charger","i":3},
"udcspnt": {"unit":"mV","value":403000.00,"isparam":true,"minimum":50000.00,"maximum":420000.00,"default":403000.00,"category":"Charger","i":4},
"udclim": {"unit":"V","value":398.00,"isparam":true,"minimum":50.00,"maximum":420.00,"default":398.00,"category":"Charger","i":5},
"timelim": {"unit":"minutes","value":240.00,"isparam":true,"minimum":-1.00,"maximum":10000.00,"default":-1.00,"category":"Charger","i":6},
"inputype": {"unit":"0=Type2, 1=Type2-3P, 2=Type1, 3=Manual, 4=Manual-3P","value":2.00,"isparam":true,"minimum":0.00,"maximum":4.00,"default":1.00,"category":"Charger","i":7},
"cancontrol": {"unit":"0=Off, 1=On","value":0.00,"isparam":true,"minimum":0.00,"maximum":1.00,"default":0.00,"category":"Charger","i":8},
"enablepol": {"unit":"0=ActiveHigh, 1=ActiveLow","value":0.00,"isparam":true,"minimum":0.00,"maximum":1.00,"default":0.00,"category":"Charger","i":9},
"idckp": {"unit":"","value":1000.00,"isparam":true,"minimum":0.00,"maximum":10000.00,"default":1000.00,"category":"Charger","i":10},
"idcki": {"unit":"","value":10000.00,"isparam":true,"minimum":0.00,"maximum":10000.00,"default":10000.00,"category":"Charger","i":11},
"pin": {"unit":"","value":0.00,"isparam":true,"minimum":0.00,"maximum":67108863.00,"default":0.00,"category":"Charger","i":12},
"opmode": {"unit":"0=Off, 1=Run","value":0.00,"isparam":false},
"state": {"unit":"0=Off, 1=Enable, 2=Activate, 3=EVSEActivate, 4=Stop","value":0.00,"isparam":false},
"uptime": {"unit":"s","value":849.00,"isparam":false},
"version": {"unit":"4=1.07.R","value":4.00,"isparam":false},
"lasterr": {"unit":"0=NONE, 1=CHARGERCAN, 2=CHARGERFAULT, 3=EXTCAN,","value":0.00,"isparam":false},
"uaux": {"unit":"V","value":13.31,"isparam":false},
"aclim": {"unit":"A","value":0.00,"isparam":false},
"hwaclim": {"unit":"A","value":0.00,"isparam":false},
"modaclim": {"unit":"dig","value":0.00,"isparam":false},
"modcmd": {"unit":"dig","value":100.00,"isparam":false},
"cablelim": {"unit":"A","value":40.00,"isparam":false},
"evselim": {"unit":"A","value":15.59,"isparam":false},
"idc": {"unit":"A","value":0.00,"isparam":false},
"udc": {"unit":"V","value":0.00,"isparam":false},
"soc": {"unit":"%","value":0.00,"isparam":false},
"proximity": {"unit":"0=Off, 1=On","value":1.00,"isparam":false},
"enable": {"unit":"0=Off, 1=On","value":0.00,"isparam":false},
"canenable": {"unit":"0=Off, 1=On","value":0.00,"isparam":false},
"cpuload": {"unit":"%","value":0.00,"isparam":false},
"c1stt": {"unit":"","value":0.00,"isparam":false},
"c1flag": {"unit":"0=None, 1=Enabled, 2=Fault, 4=CheckAlive","value":0.00,"isparam":false},
"c1tmp1": {"unit":"°C","value":0.00,"isparam":false},
"c1tmp2": {"unit":"°C","value":0.00,"isparam":false},
"c1tmpin": {"unit":"°C","value":0.00,"isparam":false},
"c1uac": {"unit":"V","value":0.00,"isparam":false},
"c1iac": {"unit":"A","value":0.00,"isparam":false},
"c1udc": {"unit":"V","value":0.00,"isparam":false},
"c1idc": {"unit":"A","value":0.00,"isparam":false},
"c2stt": {"unit":"","value":0.00,"isparam":false},
"c2flag": {"unit":"0=None, 1=Enabled, 2=Fault, 4=CheckAlive","value":0.00,"isparam":false},
"c2tmp1": {"unit":"°C","value":0.00,"isparam":false},
"c2tmp2": {"unit":"°C","value":0.00,"isparam":false},
"c2tmpin": {"unit":"°C","value":0.00,"isparam":false},
"c2uac": {"unit":"V","value":0.00,"isparam":false},
"c2iac": {"unit":"A","value":0.00,"isparam":false},
"c2udc": {"unit":"V","value":0.00,"isparam":false},
"c2idc": {"unit":"A","value":0.00,"isparam":false},
"c3stt": {"unit":"","value":0.00,"isparam":false},
"c3flag": {"unit":"0=None, 1=Enabled, 2=Fault, 4=CheckAlive","value":0.00,"isparam":false},
"c3tmp1": {"unit":"°C","value":0.00,"isparam":false},
"c3tmp2": {"unit":"°C","value":0.00,"isparam":false},
"c3tmpin": {"unit":"°C","value":0.00,"isparam":false},
"c3uac": {"unit":"V","value":0.00,"isparam":false},
"c3iac": {"unit":"A","value":0.00,"isparam":false},
"c3udc": {"unit":"V","value":0.00,"isparam":false},
"c3idc": {"unit":"A","value":0.00,"isparam":false},
"serial": {"unit":"","value":"87184258:49548566:670FF54","isparam":false}

[timbradley]

Timestamp,
2022-09-25T08:47:54.574,0.00
2022-09-25T08:47:54.848,0.00
2022-09-25T08:47:55.187,0.00
2022-09-25T08:47:55.457,0.00
2022-09-25T08:47:55.725,0.00
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2022-09-25T08:47:58.203,0.00
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2022-09-25T08:47:59.065,0.00
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2022-09-25T08:48:00.658,0.00
2022-09-25T08:48:00.952,0.00
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2022-09-25T08:48:01.567,0.00
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2022-09-25T08:48:02.182,0.00
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2022-09-25T08:48:02.737,0.00
2022-09-25T08:48:03.004,0.00
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2022-09-25T08:48:03.835,0.00
2022-09-25T08:48:04.120,0.00
2022-09-25T08:48:04.388,0.00
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2022-09-25T08:48:07.997,0.00
2022-09-25T08:48:08.327,0.00
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2022-09-25T08:48:09.655,0.00
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2022-09-25T08:48:10.265,0.00
2022-09-25T08:48:10.529,0.00
2022-09-25T08:48:10.796,0.00
2022-09-25T08:48:11.065,0.00
2022-09-25T08:48:11.341,0.00
2022-09-25T08:48:11.779,0.00
2022-09-25T08:48:12.108,0.00
2022-09-25T08:48:12.374,0.00
2022-09-25T08:48:12.730,0.00
2022-09-25T08:48:12.995,0.00
2022-09-25T08:48:13.338,0.00
2022-09-25T08:48:13.607,0.00
2022-09-25T08:48:13.873,0.00
2022-09-25T08:48:14.139,0.00
2022-09-25T08:48:14.420,0.00
2022-09-25T08:48:14.684,0.00
2022-09-25T08:48:14.949,0.00
2022-09-25T08:48:15.291,0.00
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2022-09-25T08:48:15.894,0.00
2022-09-25T08:48:16.163,0.00
2022-09-25T08:48:16.436,0.00
2022-09-25T08:48:16.707,0.00

[timbradley]

A view of us trying the second charger, feeding 12V to pin three to turn on power modules.

[timbradley]

A bit more information.

The board is not outputting any of the required voltages on connector A. No "OUT2 - AC present" on pin A1, in other words. A6 has nothing either.

Thanks, in advance, for any suggestions you can offer.

[EV_Builder]

Do you have a can log?

[timbradley]

Sorry, where can I access the can log? We can't seem to find any options in the interface to grab one.

[arber333]

Sorry, where can I access the can log? We can't seem to find any options in the interface to grab one.

You select debug in serial interface in case of the open code. Or if you have second code connect CAN on the board to the outside and record msgs there.
EDIT: Yes dont forget to sort out the CAN resistor...

[NickB]

A bit more information.

The board is not outputting any of the required voltages on connector A. No "OUT2 - AC present" on pin A1, in other words. A6 has nothing either.

Thanks, in advance, for any suggestions you can offer.

I am also experiencing the same situation. The control board is fully powered on and when the AC is connected the board does not output the AC Present 12v.

Any recommendations?

[Jack Bauer]

Naturally you have soldered the can jumper under the wifi module?

[NickB]

Yes, the Can jumper is soldered and I have verified it is a good solder joint.

[EV_Builder]

Make a CAN Log and post as attachment and I can check.

[NickB]

Perfect, I will pull a CAN log shortly and post it.

Apologies in advance for the spam.

Edit: I hooked up a Arduino nano with the Rst and Gnd jumped intern making it a serial adapter using the FTDI chip. I hooked It up to Conn9
Gnd to Gnd
Rx to RX
Tx to TX
5v to 5v

And the board did not power up. I removed the 5v and connected 3v to the programing port which powered up the board but it did not display any messages on the serial monitor.

I feel like I am missing something simple? Any advice?

My board is the v5ab3.

I plan on trying to hook up to CAN from CON 2 to a usb to CAN adapter.
Or is there a better way to pull the CAN log that I am missing?