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Tesla 10Kw Open Source Charger Controller

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#281 ·
Do they switch the modules from all being on one phase to each having their own phase?

Are the relays for the coupling of 'AC' lines onto the battery for DC fast charging?

The configuration to do the current command per module is based on if the modules share a phase or are in a three phase configuration.
 
#282 ·
Tomdb said:
Do they switch the modules from all being on one phase to each having their own phase?
Click to expand...
Yes.

Tomdb said:
Are the relays for the coupling of 'AC' lines onto the battery for DC fast charging?
Click to expand...
Yes, the two (US) or four (EU) contactors on the HVJB PCB are only used to connect the 'AC' lines from the charging connector to the DC bus bars that connect to the battery, motors, and front HVJB.

I'll try to publish the HVJB schematic next week to clarify this.

Tomdb said:
The configuration to do the current command per module is based on if the modules share a phase or are in a three phase configuration.
Click to expand...
Last time I drove a Tesla Model S it would automatically select between one phase, three phase, and DC configuration depending on what's available at the charging station. My guess is the charger is making this decision based on the voltage it senses on the 'AC' inputs.
 
#283 ·
Kevin, i am looking forward to seeing the HVJB schematic for an EU box.

I have worked on the code some more, now the debug will show every 500ms instead of other code related. This makes it alot more readable.

The next step would be to actually charge a battery, however I am still waiting on parts to do it safely. Like the Type 2 Socket I ordered yesterday.

So if anyone has a charger with the opensource board in it and would like to do some testing please go a head, as I would like to prove out the code.
 
#284 ·
We're putting together a dual Gen2 charger setup. At the track, ,we will have a separate 208V, 50 amp circuit going into each charger. We will no be using an EVSE. Are we going to be able to command > 40 amps so we can still obtain the 3.3kW/module?
 
#285 ·
I could include a manual override, so that you can setup the charger to pull your desired AC current set by serial comms or can.

And then have am input just to switch the charge on by applying 12V.

Anything is possible, but how would you control/set/monitor you charging voltage?
 
#286 ·
Tomdb said:
I could include a manual override, so that you can setup the charger to pull your desired AC current set by serial comms or can.

And then have am input just to switch the charge on by applying 12V.

Anything is possible, but how would you control/set/monitor you charging voltage?
Click to expand...
I think going with ESP32 would be great so any settings can be done via BLE or WiFi using just mobile phone. ESP32 can has can support and more can be added via SPI and MCP 2515

Sent from my Z1 using Tapatalk
 
#287 ·
So the charger isn't current limited to 40A? I know that if you plug a Model S into a charger being fed with 208V instead of 240V, the charge power will be decreased proportionally. Yes, we were planning on starting charge when 12V was applied. We will run the charger flat out at in the constant current phase, with a CV setpoint of approx. 400V. We will have our datalogger and BMS both monitoring charging - as well as our eyes on the gauges.
 
#288 ·
tiger82 said:
So the charger isn't current limited to 40A? I know that if you plug a Model S into a charger being fed with 208V instead of 240V, the charge power will be decreased proportionally. Yes, we were planning on starting charge when 12V was applied. We will run the charger flat out at in the constant current phase, with a CV setpoint of approx. 400V. We will have our datalogger and BMS both monitoring charging - as well as our eyes on the gauges.
Click to expand...
On the charger it says 48A, 16A per module and 45A DC.

Sent from my Z1 using Tapatalk
 
#291 ·
Kevin Sharpe said:
First draft HVJB schematic released (see here) :)

I'll produce something similar for the AC switching box in the near future :)
Click to expand...
Hi Kevin,

Very useful diagram. Thanks.

Some component questions...

1) U1 (ACS758KCB-150B-PFF-T), F7 (100A) and J6
- Is this the connection to the Front HVJB that links to all the HV accessories (cabin heater, AC, DCDC, coolant heater)?

2) J11
- For DC charging control and the economizer for the contactors?

3) Is the US version just a delete of two contactors and associated lines?

Thanks
Jeff
 
#293 · (Edited)
DrJeff said:
1) U1 (ACS758KCB-150B-PFF-T), F7 (100A) and J6
- Is this the connection to the Front HVJB that links to all the HV accessories (cabin heater, AC, DCDC, coolant heater)?
Click to expand...
Correct, it's the power source for the Front HVJB.

DrJeff said:
2) J11
- For DC charging control and the economizer for the contactors?
Click to expand...
J11 plugs into the control board which has the CAN controller and monitors functions like the reed switches used to detect when the HVJB case is open and when the HV cable is disconnected.

DrJeff said:
3) Is the US version just a delete of two contactors and associated lines?
Click to expand...
The EU and US versions use the same PCB. The only difference is the US build removes two contactors (which are not required because the Tesla charging connector only has two power pins unlike the EU charging connector which has four power pins).
 
#294 ·
Tomdb said:
Where does the AC switching box live? I have not really noticed it on a Tesla.
Click to expand...
It's a small metal box that bolts onto the AC output 'slot' on the EU HVJB (see photo in this post). It's switching the AC signals between the HVJB and the Chargers. I'll produce a drawing when I get a moment :)
 
#295 ·
Quick question. Not sure if off topic.

Does the HVJB contain the precharger resistance? Or is there any additional pre charger resistors in the car? The only picture I found of the RARA 23 Ohm Wirewound resistor appears to be too low to be able to precharge from 0v to 420v without exceeding the watt rating.
 
#296 ·
annerajb said:
Quick question. Not sure if off topic.

Does the HVJB contain the precharger resistance? Or is there any additional pre charger resistors in the car? The only picture I found of the RARA 23 Ohm Wirewound resistor appears to be too low to be able to precharge from 0v to 420v without exceeding the watt rating.
Click to expand...
Ok I also have a question about precharge, not sure if this was mentioned before. What should I use as precharge. Also what is the sequence to be done manually if I wanted to use existing arduino code. I've built test rig based on arduino and MCP. The problem is I do enable at the power on and activate manually. I also have no precharge resistor connected.

Sent from my Z1 using Tapatalk
 
Discussion starter · #297 ·
Precharge is handled in the Tesla battery by the bms. The drive unit and charger are both precharged from here. External or manual precharge will be required to run the charger stand alone.
 
#300 ·
Tomdb said:
Charger will not work without seeing a battery voltage at the output.

So an easy way to do this would be with a light bulb across a contactor. So you wait for some time, or measure it using a multimeter befor closing the contactor.
Click to expand...
So can I connect it directly? I see some sparks while connecting is this what precharge eliminates?

Sent from my Z1 using Tapatalk
 
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