Roadster PEM failure

[petergrub]

Do the different PEMs have different part numbers and are all Reman PEMs universal?

Universal PEM: TPN 0600276899 rev AC; SAP 6008983 (PEM - 2.01 Remanufactured)
Standard PEM: TPN 0600276800 rev AC; SAP 6005203 (PEM)
Sport PEM: TPN 0600221601 rev AC; SAP 6004128 (PEM - US, SPORT )

I don't know for sure if all Remanufactured PEMs are universal, but it would be a smart move on Tesla's part to do that. I also don't know if the Firmware installed determines whether you have the Sport performance, or if there is a software switch to enable it. Most Roadsters already have the sport motor installed. I just pulled a sport motor a couple of weeks ago from a non-sport model.

 

[hallvardr]

I have now disconnected the PEM again to have it looked at. Hopefully it will be easy to find the troublemaker. I also got the log file out for the first time. Is the only way to get the error messages out in text to run DOS commands? Or is there an easier way to getting it all out.

 

[petergrub]

I have now disconnected the PEM again to have it looked at. Hopefully it will be easy to find the troublemaker. I also got the log file out for the first time. Is the only way to get the error messages out in text to run DOS commands? Or is there an easier way to getting it all out.

DOS is your best route right now. I use Scott's log parser which I find to be the easiest to use (drag and drop files into the command window and then tell it to output to a CVS file). I'm personally working on one to use the best features of both Tesla GLOP by Doug and log_parse by Scott, but it's not done yet.

 

[hallvardr]

I can get the programs started, but have never done anything in DOS so am stuck as soon as I'm in the program...

 

[PV-EV]

Tom Saxton at idleloop.com has a VMS parser for OSX. Search VMS log parser for Tesla Roadster. Good instructions and other information.

 

[hallvardr]

Tom Saxton at idleloop.com has a VMS parser for OSX. Search VMS log parser for Tesla Roadster. Good instructions and other information.

Thanks, but unfortunately just no OSX here :/

 

[petergrub]

For those of you interested in looking at you Roadster log files I have put together instructions on how to convert your log file to a CSV for easy reading using scott451's Log_Parse_v18 on Windows computers.

 

[hallvardr]

Thanks, Peter! brilliant write up!

Back to the PEM. It's out again and all 8 fuses have been found and checked, and they are whole... ?

Thanks to your idiot proof recipe for getting the logs out, here are my last error codes:

DMC HW: PhaseC Low Side Desat Fault
DMC FW: Poll Power
DMC FW: PhaseA OverCurrent warning
DMC FW: PhaseB OverCurrent warning
DMC FW: PhaseC OverCurrent warning

 

[petergrub]

Back to the PEM. It's out again and all 8 fuses have been found and checked, and they are whole... ?

Check the continuity to ensure the fuse is still whole inside where you can't visibly inspect. Most modern multimeters have a continuity check function that beeps when a short occurs. The other thing you can try is measuring the resistance, which should be an Ohm or less.

 

[hallvardr]

Is fuses the only thing that makes sense for those error codes?

 

[PV-EV]

If the vehicle will charge the 913 fault indicates a likely internal PEM short. It could also be a motor problem but being as you just worked on the PEM I think the motor problem is unlikely.

 

[thefortunes]

There are some small capacitors on that board (I had blown two on mine).

I'm not sure if it would charge with them blown, but that is what I would check next.

 

[hallvardr]

Victory!! PEM repair and upgrade is finally completed successfully! Just in time for a roof off weekend drive thanks so much for all the tips and help. It has been much appreciated!! Looks like the problem was 6 blown resistors. All IGBTs changed on one boards and ceramic strips installed. Done a couple of rides now, and things are looking good. I pulled the service plug on the battery and it has barely lost any juice in the 3 months it took to fix the PEM.

 

[Rotarypower]

Awesome @hallvardr! Congrats and good job. Can you provide more details and pictures? Which resistors? Oh and what ceramic strips did you go with? Please share as much as you can, as it appears now that TMC is now our database for current and future owners to resolve these issues.

Now seeing threads indicating Tesla isn’t supporting customers (other than wholesale replacements with extreme lead times) with battery and PEM issues means we will have to take matters into our own hands and repair this incredible vehicle ourselves.

 

[Jonathanm]

Hey Mate good job...curious about the resistors as well...did you use 1mm ceramic or did you find something a little thicker?

BTW Tesla want me to sign a waiver before they will touch my car - because I fixed my PEM...just wanted the latest software...must admit I find this pretty strange when they are not able to offer a viable solution (10K€ to fix a power inverter is not in my book viable)...If anybody is interested I will post the waiver...get the impression we are a little like the poor relation...feeling a bad taste in the mouth...guess we have to learn to do it without them...but they need to give us the drawings and manuals...

 

[hallvardr]

The strips I went with are here:
Roadster PEM failure

Pictures of the damaged PEM is the next post. All IGBT's on that board was changed. And the resistors that were broken was the ones closest to the damaged cooler.

 

[hallvardr]

A little more info: The material I used is 1mm which has been used with success by Gruber Europe. The strengt on the material Grubes has uses is 300, the one I used is 450. I was also in direct contact with the company producing the material explaining the use (which they found very interesting) and they recommended the one I got. So I feel very confident that it should be a very suitable material.

Tesla did not update my software on my last service so I am supposed to come in and get that done sometime. So it will be interesting to see if they will do work on mine, or if I have to sign something too.

If anyone have more questions, I will answer as good as I can.

 

[Rolf68]

A little more info: The material I used is 1mm which has been used with success by Gruber Europe. The strengt on the material Grubes has uses is 300, the one I used is 450. I was also in direct contact with the company producing the material explaining the use (which they found very interesting) and they recommended the one I got. So I feel very confident that it should be a very suitable material.

If anyone have more questions, I will answer as good as I can.

Hello Hallvardr.

Thanks for all the info. I opened the pdf document you attached that describes the Rubalit and Alunit, but I wonder what did you exactly order, there are several products in the flyer. Did the german company cut the strips at the exact dimensions or did you cut that yourself? Last question (if you don't mind answering this one) what was the price for all the strips ?

Thanks a lot !

Best regards

 

[hallvardr]

The one I got was: CT-R708S
They cut the strips for me: 167x32x1mm
Price Including shipping was 187Euro

 

[Rolf68]

The one I got was: CT-R708S
They cut the strips for me: 167x32x1mm
Price Including shipping was 187Euro

Thanks for the info