Category: EV

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Model 3 Shortbrick 2170 Cell Extraction – Structural block mythbusting

Model 3 LR 2170 Cell Extraction – Finally, an opportunity arose for a new project, to purchase and save the entire battery pack, demonstrating that the entire battery is never replaced as whole (except in Nissan Leaf or Mercedes with programmed defects). One faulty cell in the structural block of 25S was discharging one group, not disabling the vehicle but reducing the range and charging level. In situations where the group’s discharging is permanent, it is crucial to repair/remove the faulty cell as quickly as possible. If the voltage of that group drops completely and remains empty for more than a month below 2.5V, it leads to permanent damage to the parallel group and permanently irreparable condition of that particular block (out of a total of 4). We bought the battery for the purpose of developing repair solutions, creating tools, and repair methods. For the first time, we attempted and succeeded using the highest quality tools and materials to assemble the battery and later perform a road test to confirm proper balancing, charging, discharging, and that there were no other damaged cells except that one. Recently, we were contacted by the French LeMonde tabloid to give our opinion on possible EU regulations on battery design, where they directly obstruct Tesla’s and other NON-EU manufacturers’ innovation, directing how bureaucrats would want the battery pack to be designed, allegedly in fear of how repairs will be done and to “protect customers” whom they do not protect from domestic profiteers. There is no irreparable battery, there is no problem that cannot be solved, it may be a more or less complex procedure, but it can never be impossible (except in the case of Nissan Leaf). The repairability problem does not lie in the design, such as the “structural pack,” but in the availability and accessibility of parts for repair, designing battery systems without programmed failures, availability of electronic controllers for battery systems, cells, and similar approaches to a sustainable circular economy… the ones that EU manufacturers do not implement.

Model 3 LR 2170 Cell Extraction – Napokon nam se ukazala prilika za novi projekat da kupimo i spasimo cijeli baterijski paket, demonstriramo da se nikad ne mjenja cijela baterija (osim na Nissan Leaf ili Mercedesu sa programiranim kvarom). Jedna neispravna ćelija u strukturnom bloku od 25S je praznila jednu grupu, nije onesposobila vozilo vec je smanjila domet i razinu punjenja. U situacijama gdje je pražnjenje grupe trajno, izuzetno je bitno u sto kracem roku sanirati kvar, ako se desi da potpuno padne napon te jedne grupe i ostane prazno duze od 1og mjesec ispod 2.5V tada dolazi do trajnog ostecenja paralelne grupe i trajnog nepopravljivog stanja tog jednog bloka (od ukupno 4 koliko ih ima). Bateriju smu otkupili u svrhu razvoja riješenja za reparaciju, izradu alata i metoda reparacija. Prvi put smo pokušali i uspjeli korištenjem najkvalitetnijih alata i materijala kako bi bateriju sklopili i napravili roadtest da potvrdimo da se pravilno balansira, puni, prazni i da nema još oštećenih drugih ćelija osim te jedne. Nedavno su nas zvali iz Francuskog LeMonde tabloida da damo svoje mišljenje na mogucu EU regulativu dizajna baterija gdje se direktno obstruira inovativnost Tesle i drugih NON EU proizovdjača gdje bi dirigirali kako bi birokrati zeljeli da se dizajnira battery pack jer tobože su u strahu kako će se popravljati i da “zaštite kupce” koje ne štite od domaćih lihvara. Ne postoji nepopravljiva baterija, ne postoji problem koji je ne riješiv, može biti zahvat teži ili lakši ali nemoguć ne moze biti nikada (osim kod nissan leaf). Problem popravljivosti ne leži u dizajnu, “structural pack” recimo, već dobavljivosti i dostupnosti dijelova za reparaciju, dizajniranjem baterijskih sustava bez programiranih kvarova, dostupnosti elektroničkih kontrolera baterijskih sustava, ćelija i slicnih olakotnih pristupa odrzivoj kruznoj ekonomiji… onoj koju EU proizvodjači ne provode.

Part number:
Errors: BMS_A064, BMS_A079, BMS_A066
Tesla Price: 8900Eur
EVC: 4500Eur

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Real Tesla Multimilionaire is P85 with 1.800.000 km under the belt

We were visited by “Multi Millionaire” Hansjörg von Gemmingen-Hornberg, a millionaire in kilometers driven with his first Tesla S P85 from 2013. One of the most important figures in the eMobility sphere, as with every kilometer he drove, he shattered prejudices and stereotypes, leaving a legacy of trust in EVs for future generations. He achieved something that some wouldn’t dare with a fossil-fuel car in 9 years. He drove the vehicle when charging stations were scarce. Back in 2008, he was one of the first Tesla Roadster owners and possibly the only one who drove a Roadster for 700,000 km. After that, with the Model S, he broke records not only his own but also worldwide.

Recently, we’ve been writing about how RMN motors (repaired in Tesla Tilburg) have become completely unreliable, as confirmed by other clients and by Hansjorg, who replaced 13 RMN motors in 1800000 km, while the first original PTrain Mech lasted 800,000 km. Following the recommendation we published in a letter to Tesla that preventive repairs were necessary, our colleague realized that it might be time for an overhaul or towing. He had a good feeling, because if he hadn’t contacted us, the last motor would have failed at 1,000 km, at 150,000 km (beyond our recommendation), as the coolant seal had already failed and leaked antifreeze into the bearing area where the only barrier was the bearing grease to prevent it from entering the stator and causing a “short circuit.” He came just in time, and we saved the motor, restored it, installed some of our “patch” improvements, and permanently resolved the antifreeze leakage. This EVC Reman motor is ready for the next half a million kilometers at least.

We are grateful for the invaluable trust placed in us, but from our side, we felt the need to send a message. A message that Tesla and Elon forgot, that his achievement deserves official recognition, reward, and acknowledgment because what he accomplished is something no one else will even attempt for generations. As a small EVC, we will do what Tesla didn’t; we will reward him with free service for the electric motor that outlasts their RMN motors.

If you need EVC Academy full training at our facility to learn complete know-how you can order training here:


https://evclinic.eu/evc-knowhow-academy/tesla/large-drive-unit-ldu/ms-mx-large-du-miling-buzzing-sound-and-degraded-isolation-repair-manual-bms_w035-bms_f07120236118124/

HRVATSKI

Stigao nam je “Multi Milijunaš” Hansjörg von Gemmingen-Hornberg, milijunaš u predjenim kilometrima sa prvom Teslom S P85 iz 2013 godine. Jedan od najbitnijih osoba iz eMobility sfere jer je svakim svojim kilometrom rušio predrasude i stereotipe, njegov footprint će ostaviti nasledje povjerenja u EV svim budućim generacijama. Postogao je nesto sto se neki nebi usudili ni sa fosilcem u 9godina. Kretao je se vozilom kad nigdje nije bilo ni punionica. Davne 2008 godine jedan je od prvih Tesla Roadster vlasnika i moguće jedini koji je sa roadsterom napravio 700000km. Nakon toga sa Model S ruši rekorde ne samo svoje već i svjetske. Kako smo počeli pisati zadnje vrijeme da su RMN motori (reparirani u Tesla Tilburgu) postali totalno nepouzdani, sto smo potvrdili i sa drugim klijenti a i sa Hansjorg koji je promjenuo 13 RMN motora u 1.800.000 km, dok je prvi PTrain Mech originalni napravio 800.000km. Po preporuci koju smo objavili u pismu Tesli da je preporuka da se preventivno repariaju tako je i nas kolega skuzio da je mozda vrijeme ili za remont ili za šlepu. Imao je dobar feeling, jer da se nije javio ovaj zadnji motor bi otkazao za 1000km na 150000km (sto je preko nase preporuke) jer je coolant seal vec probio i pustio antifriz u zonu ležaja gdje je jedina prepreka mast u lezaju da udje u stator i napravi “kurzschluss”. Na vrijeme je dosao, motor smo spasili, restaurirali, ugradili par naših “patch” unaprijedjenja i trajno rijesili prodor antifriza. Ovaj EVC Reman motor je spreman za sledećih pola milijuna minimalno. Nama je neprocjenjivo ukazano povjerenje, ali ipak sa nase strane nedostajalo je poslati i jednu poruku. Poruku koju su Tesla i Elon zaboravili da njegovo postignuce ipak zasluzuje i sluzbenu potvdu, nagradu, odgovor, jer ovo što je on uspio još niko generacijama neće ni pokušati. Mi kao mali EVC napravit ćemo ono što Tesla nije, nagradit ćemo ga besplatnim servisom elektromotora koji izdrzi vise od njihovog RMN.

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Model S85 upgrade to S100 with prototype tuned motor.

To present you first ‘Model S 100’ RWD in Europe, upgraded from healthy 85 to 100 kWh battery pack. We didnt stop there, we upgraded Large drive unit electric motor from problematic RMN to EVC tuned and optimized one for higher range and higher reliability. BMS Calculated range is lower than expected until it calibrates fully, and expected autonomy should be above 500km. Model S is Autopilot AP1 2014 with 379000km on clock with free supercharger. This project was “tuned” for my own pleasure. Thanks goes to wk057 coding tip. System is safe from SuC deactivation.

*NOT FOR SALE

Predstavljamo prvi ‘Model S 100’ sa stražnji pogonom u Europi, nadograđen s zdrave baterije od 85 na 100 kWh. No, nismo stali samo na tome, ugradilo smo i poboljšani električni motor LDU s problematičnog RMN-a na EVC model, prilagođen za veći doseg i pouzdanost. BMS trenutno prikazuje manji doseg od očekivanog dok se potpuno ne kalibrira, a očekivana autonomija trebala bi biti iznad 500 km. Model S je Autopilot AP1 iz 2014. s 379.000 km na satu i besplatnim punjenjem doživotno. Ovaj projekt je “prilagođen” za vlastiti gušt i trenutno smo spremni za Homos Balkanikus olimpijadu Zagreb Split bez odpajanja katetera i stajanja. Stavljena je Popcorn mapa za Netflix za nedaj može, stage 2 zavojnica i kondenzator, bakraći… deaktivirana je VodaUStrujiOFF, straightpipe klima u kabini filterOFF da skida i ženin puder sa lica.

*TESLA NIJE NA PRODAJU

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Tesla’s powertrain: Defying limits, rewriting legacies for 600000km on original battery.

Finally, the embodiment of what we already knew was possible but were waiting for the physical manifestation of the argument: a Tesla with its original battery and 600,000 km on the clock. A complete stranger entrusted us with a Tesla from Vienna, arriving on a tow truck without any supervision, solely based on trust from Google. Although the car was still drivable, it had a limited range of 100 km. It was the first time we personally documented such an event, and you have the honor of being acquainted with it. We were able to confirm through multiple analyses and verifications, following the owner’s statement that the battery remained untouched, as we were curious about its maximum lifespan threshold.

We had an inkling that the first-generation 1.5 battery could handle around 400,000 km before requiring servicing. However, this was mostly in cases where moisture infiltration or wiring damage were expected causes of failure. But this situation goes beyond all previous scales because the battery, hermetically sealed and free from moisture infiltration for the first time, arrived with only 10 degraded cells out of a total of 7,104 cells. These cells, due to increased internal resistance, caused significant “voltage relaxation” oscillations after periods of rest, resulting in a “brick short” discharge of one group of 74p cells, triggering the BMS_u029 flag. Without completely dismantling the entire block, these 10 cells will be replaced through a special extraction process and prepared for a bench test on a Solar UPS system. The block from the previous Tesla, which passed the gladiator bench test with an approximate capacity of 200 Ah, will be inserted into this battery pack, thus closing the loop of recycling and repair.

The battery currently operates at a capacity of 67 kWh or 195 Ah CAC, which represents approximately 11% degradation or 89% state of health (SOH). Interestingly, the first motor, previously mentioned as the P-Train MECH (not RMN), was only replaced at 500,000 km due to a humming bearing, and a new RMN motor was installed under warranty. This serves as further confirmation that Tesla’s LDU is an extraterrestrial overkill, ensuring the same quality even in the RMN model (Remanufactured). Tesla truly reigns as the king of the road and the automotive revolution, disrupting the entire legacy mindset of “moderate quality” and other imposed criteria by legacy groups, where the goal is to manufacture a vehicle that lasts only until the warranty expires, forcing you to discard and purchase a new one.

Today, fossil vehicle components are manufactured and tested up to 180,000 km in simulated environments. If they surpass this threshold, the system is deemed unsuitable for commercial sales because there is “no owner on a subscription.” On the other hand, everything we have seen, analyzed, repaired, and dismantled from Tesla demonstrates an absolute open-source contrast. Here, after 9 years and 600,000 km, the battery remains usable, having amortized the entire vehicle, and there was no need to replace the entire battery pack, as the infodemic often claims. Furthermore, we considered that the vehicle’s air conditioning was malfunctioning, and the lack of adequate cooling could have caused damage to a few cells. Currently, there is no powertrain in the world that surpasses their quality standards, and for the past 10 years, they have been relentlessly advancing, innovating, and raising the bar that not even the most established manufacturers can keep up with.

For the past 10 years, we have been hearing from mainstream infodemic spreaders that batteries cannot be repaired, that they are entirely discarded, that they cost more than the vehicle (only with the Nissan Leaf), that their lifespan is only 200,000 km, that they only last a few years… However, when we transitioned from maintaining diesel junk to EVs, every day of exploration brought enlightenment. We needed tangible confirmation, and for you, who sought the herald, here it is.

HRVATSKI:

Napokon utjelovljenje onog sto smo već i znali da je moguće ali smo čekali materijalizaciju argumenta u fizičkom obliku: Tesla sa original baterijom i 600000km na satu. Stigla nam ja Tesla od potpunog neznanca u punom povjerenju sa googla bez ikakvog nadzora na šlepi iz Beča, iako je još vozila ali limitiranim dosegom od 100km. Prvi put da smo osobno dokumentirali, da vi imate čast da je upoznate i da smo to mogli višestrukom analizom i provjerom potvrditi nakon izjave vlasnika da je baterija uistina netaknuta jer nas je zanimalo koji je to maksimalni prag zivotnog vjeka. Imali smo predozbu da prva baterija v1.5 drzi oko 400000km i da ju je potrebno servisirati, ali to je bilo vecinom kad je očekivani uzrok kvara prodor vlage ili oštećenje ožičenja. Ali ovo je izvan svih dosadasnjih skala jer baterija je bez greske hermetički zatvorena i bez prodora vlage po prvi put došla sa degradiranih 10 ćelija od ukupno 7104 ćelije, koje su zbog povećanog unutarnjeg otpora izazvale jaku oscilaciju “voltage relaxation” nakon mirovanja sto je ujedno “brick short” praznjenje jedne grupe od 74p a samim time aktiviralo i flag BMS_u029. Bez razvaljivanja kompletnog bloka 10 ćelija ce se mjenjati specijalnom extrakcijom i pripremiti za bench test na Solarnom UPS sustavu, a blok iz prethodne Tesle koja je prosla gladijator benchtest pribliznim kapacitetom od 200Ah ubaciti u ovaj battery pack tako da je zatvoren krug reciklaze/reparacije. Baterija je trenutno na kapacitetu od 67kWh ili 195Ah CAC što je oko 11% degradacija ili 89% SOH. Zanimljivo je i da je prvi motor koji smo vec spomenuli ranije P-Train MECH (Nije RMN) mjenjan tek na 500000km i samo zbog zujanja jednog lezaja je stavljen novi RMN u garanciji. Ponovno potvrda da je Teslin LDU vanzemaljski overkill samo da su zadrzali istu kvalitetu i na RMN modelu (Remanufacured). Tesla je uistinu kralj asfalta i kralj automotive revolucije, ometajući kompletan legacy mindset “umjerene kvalitete” i ostalih nametnutih kriterija legacy grupcija gdje je cilj napraviti vozilo da izdrzi garanciju pa da moras baciti i kupiti novo. Danas se proizvode sve komponente fosilca i testiraju do 180000km u simuliranom okruzenjima i ako izdrzi preko toga sustav je neprkiladan za komercijalnu prodaju jer “nemas vlasnika na pretplati”, dok sve dosad sto smo iz Tesle vidjeli analizirali probali popravljali rastavljali itd pokazuje apsolutnu opensource suprotnost. Ovdje je baterija nakon 9 godina i 600000km i dalje upotrebljiva, amortizirala je cijelo vozilo, nije bilo potrebno mjenjati cijelu kako to inače infodemičari tvrde i reparacija nije naučna fantastika. Dodatno smo uzeli u obzir da je na vozilu klima neispravna i da je mogući uzrok ostecenja par celija upravo nedostatak adekvatnog hladjenja. Trenutno po svim mjerilima ne postoji kvalitetniji powertrain na svijetu od njihovog i tu se bez kompromisa asevi već 10 godina i nemoljivo idu dalje, inoviraju i dižu skalu koju ne mogu pratiti ni najetaboliraniji proizvodjači. Slušamo već 10 godina mainstream infodemicare kako se baterija ne popravlja, kakao se cijela baca, kako je cijela skuplja od vozila (samo kod nissan leaf), kako je vjek samo 200000km, kako traje samo par godina… its medjutim kad smo sa održavanja dizel škarta prešli na EV svaki dan istrazivanja je bio prosvjetljenje. Nama je trebala materijalzirana potvrda, a vama tko je tražio vjesnik.

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Letter to Tesla – Large Drive Unit RMN failure

Dear Tesla, we have previously sent you a private letter, but this one is being made public on behalf of all Tesla owners and we know why your RMN LDU Fails. And sorry TESLA, but this time we have improved LDU to more power and more range. While conducting the EVC refurbishment process, we have observed degraded quality on REMAN drive units in 25 different instances.

When the drive unit was initially designed in early 2012, Tesla incorporated a slightly different rotor, superior wire winding isolation, and a more efficient thermal conductive epoxy. The coolant seal on the rotor was also better, and the only issue encountered at that time was milling pitch noise, which some early Tesla supporters may remember, and it was solely due to a single ball bearing made by SKF in India.

Subsequently, Tesla made design changes to certain components, but the most significant aspect is the quality of the critical parts, namely the rotor shaft seal and the stator. In the older Large Drive Units (LDUs) labeled with “P-TRAIN,” if the seal failed and coolant entered the unit, it didn’t cause irreparable damage to the stator windings. However, the new LDUs that were replaced under warranty suffered permanent damage upon any coolant ingress. We conducted several probe tests on local cars (in HR, SLO, AT) to explore different drying processes, but unfortunately, they were unsuccessful. Some cars experienced immediate failures, while others faced failures at a later stage, as depicted in the attached picture, where one phase winding almost exploded and caused a short circuit with the vehicle chassis.


We were particularly concerned about the situation that arose regarding the availability of used or new drive units. Our concern stems from the need to prioritize sustainability and repairability. The new drive units, which are priced at approximately 7000€, were not being sold to third-party workshops, raising questions about the accessibility and availability of these crucial components for repairs and maintenance.

Subsequently, we received a few drive units from Germany that had experienced significant coolant ingress, resulting in stator damage beyond repair. The isolation of these units fell below the threshold of 4.9 Mohm per drive unit or 16 MOhm per disconnected phase terminal. This situation further highlighted the importance of maintaining proper coolant sealing and ensuring the integrity of the stator to prevent such irreparable damage.

Out of the units we examined thoroughly, we discovered three pieces that were in a state of complete defect, leaving us with no viable options for repair. Through extensive research and analysis, we documented various failures in both RMN and P-TRAIN LDUs. Our findings revealed that RMN LDUs had a maximum lifespan of approximately 100,000 kilometers, while the older P-TRAIN LDUs were capable of lasting over 300,000 kilometers. The primary cause of failure in the new RMN LDUs was predominantly attributed to coolant seal issues. Additionally, we identified instances where the Reman facility had utilized a coolant seal with a single lip (it should have 3), which resulted in even faster deterioration of the LDUs (within 30,000 kilometers).


This 1002713-00-D coolant seal was with only 1 lip, and it failed on almost NEW RMN LDU from Italy.

It is important to highlight the experience of our friend Hansjörg Gemmingen, who reported having eight drive unit replacements within a mileage of 2 million kilometers. Interestingly, the first drive unit managed to last nearly 800,000 kilometers. This revelation left us puzzled 2 years ago, prompting us to delve deeper into understanding the reasons behind these variations and what we could anticipate as we embarked on research and development for the remanufacturing and lifetime repair of these complex and heavy LDU units. We must acknowledge that this project poses significant challenges due to its intricate nature and the high expectations of durability and longevity.

Repairing 100 battery packs with complex issues may seem easier compared to achieving sustainable quality and high mileage in repairing LDUs. The intricate nature of LDUs and the need for long-lasting performance make the repair process more challenging. Ensuring the drive unit reaches new high mileage requires meticulous attention to detail, quality control, and continuous improvements in the repair and remanufacturing processes. It is a demanding task that requires expertise and a commitment to delivering sustainable and reliable results.

During the initial stages of our research and development process, we conducted extensive testing by repeatedly removing, disassembling, and reassembling the drive unit approximately 16 times. This rigorous testing allowed us to evaluate the performance, durability, and reliability of the drive unit under various conditions. Through these iterative steps, we aimed to refine our repair and remanufacturing techniques to ensure optimal functionality and longevity of the drive units. We failed to repair 3 drive units completely and complexity was beyond imagination, and we know other 3rd party workshops failing too, even Tesla is failing to refurbish them.

And now we assembled that to “holy grail” opeartion manual eTraining at EVC Academy and we redesigned coolant seal issue and we redesigned, optimised and tuned stator winding.

https://evclinic.eu/evc-knowhow-academy/tesla/large-drive-unit-ldu/ms-mx-large-du-miling-buzzing-sound-and-degraded-isolation-repair-manual-bms_w035-bms_f07120236118124/

Our new coolant system cant ever ever again let coolant inside stator.
Our new stator cant ever ever get low isolation or overheating problems
Our new stator should increase range and power, decrease heating of the system
Our complete LDU assembly should last at least 700000km

This process is not just repairing the stator winding but improving it significantly and it costs pretty much as high as 3000€ with Tax included, just to repair on part.

What Owners should do and how to prevent all of this happening:
1- If you got RMN label on LDU, it will fail at 100K. You should make preventive service on stator/rotor side.
2-If you got P-Train label and you just got pitch noise comming from it, you should make preventive service on stator/rotor side or complete reman.
3-If your RMN LDU failed, consider that you are buying even lower quality LDU from Tesla.

What Tesla Inc. should do:

1-Change coolant seal supplier
2-Change stator reman supplier
3-Redesign coolant drain after seal
4-Change isolation at winding wire
5-Change thermal conductive epoxy

This drive unit can be found in:
RWD S60 S70 S75 S85 S90 P85 P90
4×4 P85D P90D P100D

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The Significance of Training and Proper Remanufacturing for BMS_U029: Beyond a Simple BMS Reset

Understanding the Risks and Importance of Resetting BMS_u029 and not repairing battery pack/blocks/cells.

We have been working on an issue related to BMS_u029 at EV CLINIC since March 2022 (https://evclinic.eu/2022/10/03/tesla-battery-repair-bms_u029/) , and we believe it’s crucial to share the findings.

The attached graphic displays four modules, two of which are from separate battery packs that came to us with a BMS_u029/Weak Short cell defect, and the other two from separate packs with a BMS_u018/Capacity Imbalance error.

These illustrations reveal something remarkable. Each red dot represents a cell that is experiencing self-discharge, occurring at a rapid rate of up to 20 mV per hour or more. When isolated from the rest of the brick, these cells discharge completely within 1 day, reaching 0 volts. (Typically, a healthy cell would discharge at a rate of <0.5 mV per day, which is a thousand times slower.)

Interestingly, the red dots are only present on the left side in the BMS_u029 column, while there are none on the right side in the BMS_u018 column. This is not a coincidence. It’s worth noting that these modules are not unique, as we have observed the exact same behavior across numerous modules.

What’s intriguing is that both the BMS_u029 and BMS_u018 modules exhibit noticeable capacity imbalances, with differences of up to 15 Ah or more in the case of the BMS_u018 modules, but it is usualy 6-10Ah. However, they manifest in two distinct failure modes.

In the case of the BMS_u018 modules, the cells themselves function fine with minimal self-discharge and can continue to operate, albeit with reduced capacity. These cells can even be repurposed or recycled for secondary use, just not in their current configuration as Model S battery modules.

On the other hand, each red dot in the BMS_u029 modules represents a potential runaway thermal event .

The top left module, apart from resembling chickenpox, is particularly alarming. Having this module in your pack would be highly undesirable, and resetting BMS errors on it is strongly not recommended if you didnt find and repair defect brick / cell.

Even the lower left module has one cell that poses a risk. If that cell shorts, it could trigger a potential runaway thermal event.

Furthermore, the BMS can identify even a single cell with the potential “weak short” and flag it as such. It latches the error to prevent inadvertent resetting or overlooking during unrelated firmware updates, system reboots, etc.

Additionally, the BMS can distinguish cells with potential weak shorts from worn and tired cells with capacity imbalances. It correctly recognizes the latter as being worn and tired, but not posing a significant threat. In fact, if the charge balance improves between cycles, the BMS will clear the BMS_u018 error and restore the battery’s normal operation, albeit at a diminished capacity.

In summary, Tesla’s BMS features are known to be exceptionally stringent when it comes to safety in battery systems. Understanding the problem referred to as “weak short” or “short to brick” took time, as it was a novel issue encountered initially by ourteam. For the BMS_u029 error, the rule is activated only when the battery remains idle for an extended period (approximately 8 hours or more) and exhibits a linear voltage drop in any of the 96S bricks. Activation triggers the w117 and u029 processes. This check is performed exclusively when the vehicle is not in use, and one out of the 76x 18650 cells in parallel becomes a consumer. The resulting damage is estimated to be in the range of €2-4. Initially, it was unclear which processor and memory stored the error flag/log and where the error transmission originated from.

It is important to say after all work and research, there is no easy way to address those issues without proper training and thats why we offere it to our partners and franchises.
https://evclinic.eu/evc-knowhow-academy/tesla/hv-battery/s-x-battery-master-training-operation-manual-2023612001/

Tesla Model S X Battery Master training

Therefore, a couple of key takeaways emerge:

  1. Tesla is not bricking these packs inoperable with OTA software updates(it is not programmed defect like found in Mercedes vehicles) or by surreptitiously modifying thresholds during MCU upgrades. The BMS_u029 weak short conditions in the latest BMS firmware are genuine and implemented for your safety. We have observed this behavior in all the BMS_u029 packs we have received. We have numerous decommissioned modules with identical results. The BMS_u029 modules have cells experiencing self-discharge, while the BMS_u018 cells are worn and tired.

During the decommissioning process, we remove the collector plates, as shown in the attached photos, to isolate each cell. We then dismantle the module as necessary to repurpose any good cells for secondary use.

  1. It is extremely important not to reset these BMS_u029 errors without addressing the underlying issues with cells.
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Renault Zoe – R240 milling sound

R240 is a newer generation drivetrain that many of us have been eagerly awaiting outside of the warranty period to see what fails on the air-cooled electric motor and the transmission differential. Two years ago, we received the first call from Varaždin regarding an EQ 453 Čmart, reporting that the motor had started milling and that the warranty claim was denied. The price of a new motor with replacement was around €4000, with only 90,000 km driven. At first, this seemed unusual for such a low mileage, but on the other hand, it wasn’t surprising considering it’s a French factory defect powertrain from the Renault Cléon factory, as if it was designed by some straight pipe, turbo diesel, DPF off, EGR off, EV-hating engineer, where not a single component was intended to be serviced or repaired (apparently, they haven’t heard of the Balkans). They even managed to fit brushes on the rotor of the three-phase motor for exciting the windings, so that there’s something to wear out. This is probably the only electric drivetrain on the planet that is both the worst and the most expensive.

For any operation on the drivetrain, the entire assembly must be removed from the vehicle. This is the first time we’re repairing the buzzing and turning defect in the drivetrain, and the restoration process is relatively straightforward. The procurement of parts, bearings, seals, and other materials is a slightly more complicated part, as one particular bearing on the jacksaft extension in the gearbox is produced by only one company in France. Fortunately, Lageros had one in stock specifically for this project.

In addition to the mentioned Smart from Varaždin and this Zoe from Slovenia, we have received several inquiries from Germany, Slovenia, and Norway on similar car mileage arround 100000km, but we haven’t had the opportunity to work on one yet. This particular case was successfully resolved at 1/4 of the cost of an authorized service at 118,000 km. The largest expense was the time required for disassembly and reassembly, followed by the cost of parts. In some cases, if there is turning and material wear in the differential, it may result in the wearing of the differential gears, where even after the complete drivetrain repair, a slight buzzing noise may remain, which is transmitted into the cabin. Gear replacement is not possible as they are not available, but in such cases, the entire restoration is still usable for the next 100,000 km until the next restoration.

It is strongly recommended to address any buzzing or turning sounds from the electric drivetrain immediately to prevent further damage.

HRVATSKI:

Renault Zoe – R240 pogon novije generacije koji već dugo iščekujemo izvan garancije da vidimo što to odlazi na zračno hladjenom elektromotoru a što na prijenosnom diferencijalu. Prije 2 godine prvi poziv smo dobili iz Varaždina za EQ 453 Čmart da je motor počeo zujati i da nisu prihvatili garanciju a cijena novog motora sa izmjenom je bila oko 4000€ na prijedjenih 90000km. Sto je na prvu čudno za tako malan broj kilometara ali na drugu i nije čudno jer to je francuski škart pogon iz Renault Cléon tvornice kojeg kao da je dizajnirao neki strejt pajp turbo dizel dpfoff egroff EV hejter inženjer gdje niti jedna komponenta nije osmišljena da se servisira i popravlja (valjda nisu čuli za balkan) gdje su na trofazni motor uspjeli uglaviti i četkice na rotoru za pobudu namotaja da se ima šta trošiti. Ovo je vjerovatno jedini električni pogon na kugli zemaljskoj koji najgori i najskuplji. Za svaku operaciju na pogonu, kompletan pogon se mora vaditi vani iz vozila. Na ovom prvi put repariramo defekt zujanja i tokarenja u pogonu i što se tiče same restaturacije proces je poprilično jednostavan. Nabava dijelova, lezajeva, brtvi i ostalog materijala je malo kompliciraniji dio jer na jacksaft produžetku rotora u mjenjaču jedan ležaj ne proizvodi nitko osim jedne firme u Francuskoj. Imali smo sreću da je Lageros imao na stanju jedan baš za ovaj projekat. Osim ovog spomenutog Smarta iz Varaždina i ovog Zoe iz Slovenije, imali smo nekoliko upita iz Njemačke, Slovenije, Norveške ali nismo imali priliku da i radimo na jednom. Ovaj je uspješno riješen za 1/4 troška ovlaštenog servisa na 118000km, najveci trosak je vrijeme demontaže i montaže a zatim trošak dijelova. U nekim slučajevima ako dodje do tokarenja i trosenja materijala u diferencijala, može se desiti da dodje do trošenja zubi diferencijala gdje i nakon reparacije cijelog pogona i dalje ostane manji zvuk zujanja zubi koji se prenosi u kabinu. Izmjena zubčanika nije moguća jer ih nema u nabavi, ali u tom slucaju kompletne restauracije cak iako ostane zujanje zubčanika cijeli sustav je realno upotrebljiv narednih 100000km do sledece restauracije. Svakako je preporuka da se svaki zvuk zujanja i tokarenja iz električnog pogona otkloni odmah kako nebi doslo do veće štete.

SLOVENSKI:


Renault Zoe – R240 je pogon nove generacije, ki smo ga že dolgo čakali, a je zunaj garancije, da vidimo, kaj odpove na zračno hlajenem elektromotorju in kaj na prenosnem diferencialu. Pred 2 letoma smo prejeli prvi klic iz Varaždina za EQ 453 Čmart, da se je motor začel ropotati, vendar garancije niso sprejeli, cena novega motorja z zamenjavo pa je bila približno 4000 € pri prevoženih 90000 km. Na prvi pogled je to nenavadno za tako majhno število prevoženih kilometrov, vendar pa na drugi strani tudi ni presenetljivo, saj je to francoski slabo narejen pogon iz Renaultove tovarne Cléon, ki ga je oblikoval nek strejt pajp turbo dizel dpfoff egroff EV sovražni inženir, pri čemer nobena komponenta ni bila zasnovana za servisiranje in popravilo (verjetno niso slišali za Balkan), kjer so uspeli v trifazni motor vgraditi še ščetke na rotorju za vzbujevalno navijanje, da se ima kaj za obrabiti. To je verjetno edini električni pogon na svetu, ki je najslabši in najdražji. Za vsak poseg na pogonu je treba celoten pogon odstraniti iz vozila. Tokrat prvič popravljamo okvaro ropotanja in vibriranja pogona, kar se tiče same restavracije, je postopek precej preprost. Težje je pridobiti dele, ležaje, tesnila in drugi material, ker nihče ne proizvaja enega ležaja, ki ga potrebujemo za ta projekt, razen enega podjetja v Franciji. Imeli smo srečo, da je Lageros imel na zalogi enega ravno za ta projekt. Poleg omenjenega Smarta iz Varaždina in tega Zoeja iz Slovenije smo prejeli nekaj povpraševanj iz Nemčije, Slovenije, Norveške, vendar nismo imeli priložnosti delati na nobenem od njih. Ta primer smo uspešno rešili za 1/4 stroška pooblaščenega servisa pri 118000 km, največji strošek je čas demontaže in montaže, nato pa strošek delov. V nekaterih primerih, če pride do vibriranja in obrabe materiala v diferencialu, se lahko zgodi, da pride do obrabe zobnikov diferenciala, pri čemer kljub popravilu celotnega pogona še vedno ostane manjši zvok ropotanja zobnikov, ki se prenaša v kabino. Zamenjava zobnikov ni mogoča, saj jih ni na voljo, vendar je v tem primeru celoten sistem dejansko uporaben še naslednjih 100000 km do naslednje restavracije. Vsekakor je priporočljivo, da se vsak zvok ropotanja in vibriranja v električnem pogonu odpravi takoj, da ne pride do večje škode.

Fault: Grinding, milling, buzzing
Part numbers: R290106596R, 290H88657R, 290H20130R, 290628587R, 290103231R, 296053480R,
OEM Renault: 3500€ + Tax
EV Clinic: 1100€ + Tax

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Tesla S/X PTC Cabin Heater

A ceramic heater that warms the vehicle during winter, mostly used in older EVs while newer ones have a more efficient heat pump system. This heater operates at a maximum power of 2.5-3.5 kW and consumes an average of around 1 kW for maintenance while stationary, which means that during winter, an EV with a 70 kWh battery could run the heater and heat the cabin for a maximum of 70 hours, although in practice it’s around 48 hours. The heater consists of 6 IGBTs that, through gate drivers, supply 400V to the ceramic heater, which blows air through it and heats the cabin. Since IGBTs, like any other chip, have a limited lifespan, especially under extreme stress, they can simply fail after 4-5 years. Sometimes a short circuit to the chassis causes insulation breakdown in the HV system, and other times the fuse in the distribution box burns out (which requires breaking your hand in three places and losing a set of tools to replace it). One of the simpler repairs, if the components are available and genuine (not AliExpress clones). In Tesla service, this part is actually surprisingly inexpensive, around €750 when new, although Tesla has the cheapest parts compared to the global competition. For example, the PTC heater in a Mercedes Smart costs over €2000. Even some fossil fuel-powered vehicles have 12V Aux PTC heaters, like VW Audi TDI.

HRVATSKI:

Keramicki grijač koji zimi grije vozilo, većinom korišten na starijim EV dok novi imaju efikasniju dizalicu topline (heat pump system). Ovaj radi max na 2.5-3.5kw snage, dok na odrzavanje trosi u prosjeku u mjestu oko 1kw sto znaci da bi zimi EV od 70kwh baterijom mogao stajati u mjestu i grijati kabinu max 70 sati dok u praksi je to oko 48 sati. Grijač ima 6 IGBT-a koji preko gate drivera otvaraju 400V na keramicki grijac dok zrak upuhuje kroz njega i grije kabinu. S obzirom da IGBT ima broj radnih sati kao i svaki čip, pogotovo ovaj koji je pod ekstremnim stresom, jednostavno otkaže u odredjenom momentu nakon 4-5 godina. Nekad kratak spoj na sasiju napravi pa imaš proboj HV izolacije a nekad izgori i osigurač u razvodnoj kutiji (kojeg da bi zamjenuo moras slomiti ruku na 3 mjesta i izgubiti set gedori). Jedan od jednostavnijih reparacija ako su komponente dobavljive i original ( ne aliexpress cloneri ) . Dio je inače smješno jeftin u Tesla servisu i nov, cca 750€, mada Tesla ima najeftinije sve dijelove od cijele globalne konkurencije. Recimo Mercedes Smart PTC heater košta preko 2000€. Čak i neki fosilci imaju 12V PTC Heater kao VW Audi TDI.

Errors: THC_d0015, THC_w0112, THC_w0238, THC_w0220,

Tesla OEM: 750€

EV Clinic : 300€ + fuse 50€

Part number: 1060432-00-C, 6007385-00-F, 1028985-00-A,

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Kia Soul – SK Innovative degradation fail

Kia SOUL EV – Our favorite EV is stuck in the throes of extreme degradation and just when you think you need a new battery, our EVC lab becomes your salvation because we repair it on component level by changing cells. The vehicle that was previously driven in hot Spain left a mark on the battery cells, which apparently damaged almost half of the battery system due to poor cooling and high operating temperatures. The story here is deeper than the degradation of the battery itself, because there is also the “degradation” of the KMAG user experience, which has become extremely unfriendly in terms of conditions and fulfillment of warranty requirements. Here, the warranty on the battery, which is still active, was completely unjustified declined, because the service book (wtf is service book for EV) is missing. The already familiar story with KMAG, where we witnessed several times the rejection of the warranty for completely unfounded reasons, for example by asking for the invoice of some first service and similar “strange” stories where they tied the general warranty to the warranty of the drive system which is extremely stupid and invented just to be the reason to reject warranty. But where KMAG “bendovers you”, EV Clinic try to save you. With a short run-in test, we isolated the worst cells of the “first layer refurbish”, replaced them with LGX cells from the Hyundai Ioniq, given to us by our colleague Peter from Slovenia and a colleague from France with almost new SK Innovative cells. We had enough to repair half a battery pack. We changed all the upper “overheated” cells and made the first test, which under the new “second layer refurbish” showed an additional 8 groups in bad condition. The third layer and the test showed that the complete group 1-14 under the passenger side is extremely bad and we decided to change the complete block by changing all cells. Through the tests, we had from the initial 50 km of range, to the 85, 105 and then at the last 118 km of range, which brought the condition of the battery to a usable state for use in the next 1-2 years, where we can only hope that some aftermarket solution for cells with approximately the same dimensions will come out. Because dimension of cells about 10.5 mm is the decisive factor.
In the second layer, we had only 19 kWh of the declared 28 kWh on measurement, which is about 65% SOH or 35% Degradation. In the last “layered refurbish”, we measured a usable 22kWh, which is about 75% SOH or 25% degradation, which is a big change in any usable case. We will remove the vehicle from the list of recommendations and suggest Kia NIRO EV, which has Active thermal control with antifreeze and coolant plate with same cells.

Kia SOUL EV – Naš omiljeni EV zaglavio u mukama ekstremne degradacije i taman kad pomisliš da ti treba nova baterija, naš lab ti postane spas. Vozilo koje je predhodno voženo u vrućoj Španjolskoj ostavilo je trag na baterijskim ćelijama koje su izgleda zbog lošeg hladnjenja i visoke radne temperature oštetile skoro pola baterijskog sustava. Ovdje je priča i dublja od same degradacije baterije, jer postoji i degradacija KMAG korisničkog iskustva koji su postali izrazito extremni po pitanju uslova i ispunjavanja garancijskih zahtjeva. Ovdje je potpuno neosnovano odbijena garancija na bateriju, koja je jos aktivna, jer nedostaje servisna knjiga (wtf servisna za EV). Već poznata priča sa KMAG gdje smo nekoliko puta svjedočili odbijanju garancije iz potpuno neosnovanih razloga, trazenjem računa nekog prvog servisa i slične nebuloze gdje su opću garanciju vezali za garanciju pogonskog sustava. Ali tamo gdje KMAG “otudji”, EV Clinic vrati. Kratkim uhodanim testom izolirali smo najgore ćelije “prvog sloja zahvata”, promjenuli LGX celijama iz Hyundai Ioniq koje nam ustupio kolega Peter iz Slovenije i kolega iz Francuske sa skoro novim SK Innovative celijama. Imali smo dovoljno za reparaciju pola battery pack. Izmjenuli smo sve gornje “overheated” celije i napravili prvi test koji je pod novim “drugim slojem zahvata” pokazao dodatnih 8 grupa u losem stanju. Treci sloj i test je pokazao da je kompletna grupa 1-14 ispod suvozaceve strane izrazito loša i odlučili smo mjenjati kompletan blok. Kroz testove smo imali od pocetnih 50km dometa, 85, 105 i zatim na zadnjem 118km dometa sto je dovelo stanje baterije u upotrebljivo stanje za koristenje narednih 1-2 godine gdje se mozemo samo nadati da ce izaci neko aftermarket rijesenje za celije priblizno istih dimenzija, jer debljija celije od 10.5mm je odlučujući faktor.
U drugom sloju smo imali od deklarirani 28kWh na mjerenju samo 19 kWh sto je od prilike 65% SOH ili 35% Degradacija. U zadnjem “slojnom zahvatu” smo na mjerenju dobili usable 22kWh sto je oko 75% SOH ili 25% degradacija što je u svakom slučaju veliki pomak. Vozilo ćemo maknuti sa liste preporuka i predložiti Kia NIRO EV koji ima Active thermal control sa antifrizom i coolant plate.


OEM KMAG Kia – 28400 EURO
EV CLINIC – 2000-6000 EURO
Part numbers: 37513-E4000, 37501-E4000, Mobis, SK Innovative,
Errors – Low range, Low SOH,

Kia SK Innovative 35Ah Cells
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Tesla Model 3 LR – DEFECTIVE BATTERY RARELY NEEDS REPLACEING AS WHOLE

I thought I’d retire in a cottage of sponsored hybrids before some Model 3 with a defective out-of-warranty powertrain came into my LAB. A failure caused by mechanical damage to the battery case at high speed on the highway. On the road, the driver picked up a piece of metal (not an n47 chain) with the right front wheel, which hit and broke the battery case in an area where it can’t even be seen behinde wheel liner. After a month of driving, due to the penetration of moisture, water, rain and other leaking oils (Punto, Passat, Golf…) the Alert that 400v is touching chasis came on, in practice called “Iso fault”. After starting the warranty process at the authorized service center because the hole was not visible, after additional checks and almost replacing the battery in the warranty, a problem was noticed and the warranty was rejected. Mechanical damage of any kind is not part of the warranty!!! There is a tolerance of case bending to the inside up to 8mm, but case penetration and water ingress are not part of it. The preliminary estimate for the battery change is €11,800, which is cheaper than the 651, n47, n57, b47, 654 diesel engines, but certainly too much for anyone to give up on that much money at once. Our task was to solve the battery without dismantling, patch the hole and dry the closed battery without taking it off the car… that means absolute improvisation and tool making with solving the problem 100%. First, we opened the umbrela valve vents on the battery, which has 2, then we made an artificial heated “greenhouse” around the battery and an irradiation system to extract moisture. We let the system run for 14 days for 10 hours to heat the case to 48 degrees while the rest of the “cooker system” does its job to extract moisture. After 2 weeks of labor Isolation returned to 4.8Mohm before and after the contactor… that means the battery is finally saved. However, repeated isolation breaches have left the security system in a locked state with error BMS_a027, an error that, with its number 027, oozes trouble as it is a FATAL FLAG (latching alert) to protect the system from further or larger problems. It limits the system permanently and the service ToolBox does not have a function like for Model S and X, which is called “ISO Counter Reset”, this time for Model Y and 3 this function has been moved to the Tilburg refurbish battery center where the battery repair team resets on the bench via CAN BUS. We solved the problem and the consequences, but now the most difficult part remains, how to clean the firmware safety system. We work for the first time, we read the processor for the first time, which fortunately does not have a locked JTAG, and we look for the HEX FLAG in the sea of data. After a few hours of work, we cleared the FLAG, redeployed the system again and BMS removed the error. VOILA, the battery was solved and the owner was saved by a 3rd party solution for the first time in the world. It means another example, that it is not necessary to change the entire battery, but to solve the problem in segments.

HRVATSKI:

Tesla Model 3 LR – NEISPRAVNA BATERIJA NIKAD SE NE MIJENJA CIJELA – Mislio sam da ću otići u mirovinu u vikendici sponzoriranih hybrida prije nego mi dodje neki Model 3 sa defektnim pogonom izvan garancije. Kvar koji je uzrokovan mehaničkim oštećenjem baterijskog kućišta pri većoj brzini na autocesti. Vozač je na cesti pokupio desnim kotačem komad metala (nije n47 lanac) koji je lupio i razvalio kućište baterije u zoni gdje se ne vidi ni na dizalici jer bas tu pokriva PVC wheel liner. Kroz mjesec dana vožnje zbog penetracije vlage, vode, kiše i ostalog ulja (punto, passat…) upalila je se greška da 400v probija na šasiju, u praksi zvan “Proboj izolacije”. Nakon započete garancije u ovlaštenom servisu jer rupa nije bila vidljiva, nakon dodatnih provjera i skoro pa zamjene baterije u garanciji uočen je problem i garancija je odbijena. Mehanička oštećenja bilo kojeg oblika nisu dio garancije!!! Postoji tolerancija udubljenja kućišta do 8mm ali proboj kućišta i voda nisu dio toga. Predračun za izmjenu je 11800€ što je jeftinije od 651, n47, n57, b47, 654 i ostalih nikad ništa motora, ali svakako prevelika svota za bilo koga i čega. Zadatak nam je bio da riješimo bateriju bez demontaže, zakrpamo rupu i osušimo zatvorenu bateriju… znači apsolutna improvizacija i izrada alata a da se problem riješi 100%. Prvo smo otvorili oduške na bateriji koji ima 2, zatim smo napravili umjetni plastenik oko baterije i sustav ozračivanja za izvačenje vlage. Sustav smo pustili da radi 14 dana po 10 sati da zgrije kućište na 48 stupnjeva dok ostata “pastenika” radi svoj posao. Nakon 2 tjedna izolacije se vratila na 4.8Mohm prije i poslje kontaktora… to je to baterija spašena. Medjutim uzastopni proboj izolacije je ostavio sigurnosni sustav u zaključanom stanju sa greško BMS_a027, greška koja svojim brojem 027 odiše problemom jer je to FATAL FLAG da zaštiti sustav od daljnjih ili većih problema. Limitira sustav trajno i servisni ToolBox nema funkciju kao za Model S i X koja se zove “ISO Counter Reset” ovaj put za Model Y i 3 ta funkcija je preseljena u Tilburg refurbish battery centar gdje ekipa koja reparira baterije resetira na stolu preko CAN BUS. Mi smo riješili problem i posljedice ali sad je ostao najteži dio, kako očistiti firmware safety sustav. Prvi put radimo, prvi put čitamo procesor koji sva sreća pa nema zaključan JTAG i tražimo HEX FLAG u moru podataka. Nakon par sati posla očistili smo FLAG, napravili redeploy sustava opet i BMS je maknuo grešku. VOJLA, baterija je riješena i vlasnik spašen 3rd party riješenjem po prvi put u svijetu. Znači još jedan primjer, da nije potrebno mjenjati cijeli bateriju već riješiti problem u segmentima.

Errors: BMS_a027 , BMS_f027, BMS_w027, BMS_a170
Part number: 1104423-00-N, 1106394-01-H,
Processor: TMS320LS , SPC5746CSMKU6 1N84S
Tesla OEM: 11800€ (inc VAT)
EV Clinic pricelist:
*diesel is cheaper – 69000€
*hybrid is better – 96000€
*ev is better – 1200€