NEW PCS (Power Conversion System) Failure & Replacement News

[kpanda17]

I have G since Jan, running gread

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[Dazureus]

I just got my truck back from service for the cantrail recall, lightbar recall, and PCS2 replacement. Cantrail has the stud bump now, but it's not too annoying. Lightbar was completely replaced and additional brackets installed. I had to reconnect the wiring harness and remove the blackout strip. PCS2 replacement is the T2-G revision and appears to operate normally. I had to wait 3 months for the PCS2 and service time took almost a week due to high repair volume and only 3 HV techs available. My service center provided a new Model X Plaid as a loaner. It was nice being incognito again on the streets, but the steering wheel made me feel like I was driving a bus.

 

[roadrunner32]

I just got my truck back from service for the cantrail recall, lightbar recall, and PCS2 replacement. Cantrail has the stud bump now, but it's not too annoying. Lightbar was completely replaced and additional brackets installed. I had to reconnect the wiring harness and remove the blackout strip. PCS2 replacement is the T2-G revision and appears to operate normally. I had to wait 3 months for the PCS2 and service time took almost a week due to high repair volume and only 3 HV techs available. My service center provided a new Model X Plaid as a loaner. It was nice being incognito again on the streets, but the steering wheel made me feel like I was driving a bus.

What is the T2 part of the replacement ?

 

[Dazureus]

What is the T2 part of the replacement ?

There's a 1777777-12-G which is still affected by the PCs failures. Supposedly the 1777777-T2-G isn't affected, although some forum users are still reporting some kind of PCS related warning even after receiving the T2-G replacement part.

 

[kpanda17]

There's a 1777777-12-G which is still affected by the PCs failures. Supposedly the 1777777-T2-G isn't affected, although some forum users are still reporting some kind of PCS related warning even after receiving the T2-G replacement part.

I received T2-G in December replacing my original PCS in a 2025 July build
48amp AC/325 kw DC since, perfect
No 500kw local but waiting to find and test

 

[Bri01]

They are setting me up for my second PCS replacement in 2 months, but this time also replacing the HV harness they say they didn’t need to replace the first time. I started getting notifications again after having mine replaced to the G version two months ago. I’ve been waiting for their response to why I’m having PCS failures again after replacement. I noticed on other invoices that the High Voltage Harness was also replaced, and mine was not. So I asked them about it. Here’s my initial invoice and their response:

 

[Eka]

They are setting me up for my second PCS replacement in 2 months, but this time also replacing the HV harness they say they didn’t need to replace the first time. I started getting notifications again after having mine replaced to the G version two months ago. I’ve been waiting for their response to why I’m having PCS failures again after replacement. I noticed on other invoices that the High Voltage Harness was also replaced, and mine was not. So I asked them about it. Here’s my initial invoice and their response:

That ferrite filter seams to be vital. To me it says voltage spikes were too high for the chips in use. At least what I've seen of the design, it is a low capacitance high frequency switching system. They can be quite tricky to get right.

 

[btcrealm]

They are setting me up for my second PCS replacement in 2 months, but this time also replacing the HV harness they say they didn’t need to replace the first time. I started getting notifications again after having mine replaced to the G version two months ago. I’ve been waiting for their response to why I’m having PCS failures again after replacement. I noticed on other invoices that the High Voltage Harness was also replaced, and mine was not. So I asked them about it. Here’s my initial invoice and their response:

Interesting, they had replaced different cabling on mine.

Can confirm my August 2024 Cyberbeast PCS controller failed on me March 10th. It was plugged in and charging (Tesla L2 standard charger) when it failed.

 

[AlphaG]

Just got notification of PCS2 repair completed with ferrite round cable and HV harness replacement.

 

[Batman357]

I'm at three months waiting for parts. What is the average....

 

[Cyber Pete]

There's a 1777777-12-G which is still affected by the PCs failures. Supposedly the 1777777-T2-G isn't affected, although some forum users are still reporting some kind of PCS related warning even after receiving the T2-G replacement part.

I just got the T2-G version and ferrite cable on 6-25-26. I'm currently getting PCS2_a088 charge rate reduced alert after replacement.

 

[Loudness]

After waiting 2.5 months for parts, I had the PCS replaced on my 2024 AWD FS CT (VIN 10,5xx) last week. My invoice reflects the T2-G version and ferrite round cable as well. So far, no issues at all

 

[roadrunner32]

That ferrite filter seams to be vital. To me it says voltage spikes were too high for the chips in use. At least what I've seen of the design, it is a low capacitance high frequency switching system. They can be quite tricky to get right.

EKA, I am blown away, after diving into what this PCS2 has to do. The PCS has to be a power supply that that converts household AC to 800 volts DC with the a selectable input from 110 volts (low Amps) to 230 volts at 5amps to 230volts at 48amps. Back in the day with a full wave bridge of diodes such a device with necessary heat sinks would fill up a stand alone cabinet. There would be a big ass step up multi winding transformers for the different input voltages. And how is the selectable input currents accomplished? I have no idea. I was taken back to 50s and 60s era TVs with flyback transformers that were necessary for the high frequency high voltage horizontal retrace circuits. That very specialized transformer was what usually failed accompanied with the burning smell in TVs of that vintage. I'm almost certain flyback transformers are not used in the PCS2 circuits. AI did point out that other 800 volt EVs have had the same problem over time with their charging circuits. It is a unique problem that the designers have to wait months and years to evaluate if their revisions stand the test of time. Hmpff..... I wonder if Elon is working on this problem?

 

[mongo]

EKA, I am blown away, after diving into what this PCS2 has to do. The PCS has to be a power supply that that converts household AC to 800 volts DC with the a selectable input from 110 volts (low Amps) to 230 volts at 5amps to 230volts at 48amps. Back in the day with a full wave bridge of diodes such a device with necessary heat sinks would fill up a stand alone cabinet. There would be a big ass step up multi winding transformers for the different input voltages. And how is the selectable input currents accomplished? I have no idea. I was taken back to 50s and 60s era TVs with flyback transformers that were necessary for the high frequency high voltage horizontal retrace circuits. That very specialized transformer was what usually failed accompanied with the burning smell in TVs of that vintage. I'm almost certain flyback transformers are not used in the PCS2 circuits. AI did point out that other 800 volt EVs have had the same problem over time with their charging circuits. It is a unique problem that the designers have to wait months and years to evaluate if their revisions stand the test of time. Hmpff..... I wonder if Elon is working on this problem?

Fifth order filter on AC side
High frequency CLLC type converter with four half-bridge on each leg of AC side, back to back MOSFET switches for bidirectional blocking and possibly zero current/ voltage switching.
Half bridge on each leg of DC side

So it can set any of the 4 output lines to any voltage in DC-AC mode and control current (power) in AC-DC mode

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