Have you noticed a change in your High-Powered Wall Connector charging current levels. For instance, it may have been charging your Tesla Model 3 at 40A for years, but recently the car won’t take in more than 32A.
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Try using a different High Powered Wall Connector with 48A to rule out a HPWC fault,
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If you are experiencing the same 32A limit set up a service appointment or drive your Tesla to the nearest service center.
You may also receive a message via the Tesla app informing you the “Power Conversion System” needs replacing at a cost of… $1,738! The figure can be different than this but it’s always about or over $1700.
Why Won’t Tesla Cover My Power Conversion System Under Battery Warranty?
1. Tesla policy does not cover the Power conversion system
Despite having less than 55000 miles on the odometer, and or less than four years of ownership this error or problem will not be covered under the warranty.
Tesla service believes whatever components are in the battery’s penthouse are NOT covered as an essential part of the battery’s warranty.
The warranty explicitly states it “covers the battery pack and components.”
This statement befuddles Tesla owners many of them who ask, “How is the PSC NOT one of the battery’s components?’
If you escalate the issue to the service manager, he will claim that you are misinterpreting the language, because the warranty doesn’t say “OR components.”
It is a very contentious issue with Tesla owners who don’t see the value of a battery if its charging hardware doesn’t work?
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It is very important that you read the fine print of your Tesla warranty as many items are not covered under the warranty. Take time to consult with support to understand the policies of Tesla.
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Be ready to spend on this repair as most of the power conversion units run out of juice in less than four years. It is such a costly repair, and is NOT covered under the battery warranty
Common problem
There are several reports of that the PCS having an issue and needing to be replaced.
it is part of that battery system but one of the hardest things to do is escalate at Tesla because there are few numbers to be found.
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Tesla call lines can be congested at times. The best way is just to tweet Elon on X, might get his attention. I agree with you however, I would not give up and accept that as their final answer.
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If you have already tweeted Elon Musk but no response was forthcoming it is time to escalate to the person higher than the service manager
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You can also arbitrate or get a lawyer involved
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You can also shell out your hard-earned bucks and PAY for the repair by tomorrow.
2. Power Conversion is diminished not non existent
If your power conversion isn’t getting the FULL amperage but can do less, it is ok. For instance, instead of the complete 40amps like expected it is still able to do 32amps then your power conversion still works though in a limited way
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Drive with the less power conversion
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Use a supercharger. It will bypass the HPC and just do straight DC fast charging.
It is understandably sad that your home charging current levels have lessened but it is only a few amps of power.
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Redirect the cost of $1700 in repairs towards paying for super charging instead on the days you really NEED the juice.
But realistically on a daily basis the lost amps will be barely noticeable.
3. PCS Failure
Has your Power conversion system just broken but Tesla warranty won’t cover it? Note that the Tesla service department will tell you that this repair isn’t covered under warranty and it’s a $1700 repair cost.
Many early Model 3 owners have had their PCS unit fail. The symptom of the PCS failure is limited charging on AC power, for instance car only charges at 16A or at 32A on your 48A rated charger.
What is the PCS? This is the power conversion system (PCS) that enables AC charging.
It has 3 16A controllers that enable full 48A of current. If two of your amperage controllers have failed, you can only get 16A from your 48A level 2 charger at home. If one of your amperage controllers has failed then you 32A
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There’s a service bulletin out there for this issue on the NHTSA website. Take this to your Service Center to replace under warranty. https://static.nhtsa.gov/odi/tsbs/2018/MC-10148850-9999.pdf
4. Conditions specified in service bulletin
The SB-18-16-011 addresses a known non-safety-related condition and provides recommended technical diagnosis and repair procedures for the PCS failure.
For certain Model 3 vehicles built between June 1, 2018 and July 7, 2018., the power conversion system needs replacement.
Note that the instructions on the assume knowledge of motor vehicle and high voltage electrical component repairs, and should only be executed by trained professionals.
It lists the part numbers, part description and quantity of parts needed for the repair.
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To repair the PCS your service center or mechanic needs to refer to Service Manual procedure 16301002 and follow the outline procedure for replacing the power conversion system.
Next you needed to record the serial number of the removed power conversion system in the Repair Order.
Affected VIN(s) included Affected Model 3 vehicles built between June 1, 2018 and July 7, 2018.You can check the VIN/Bulletin Tracker or Customer/Vehicle profile to determine applicability of this bulletin for a particular vehicle.
4. Arbitration decision
In January 2023 Mark D. Larsen lost a case concerning the warranty coverage of the PSC system in a matter arbitrated by the American Arbitration Association.
The arbitrator sided with Tesla not with the consumer -Mark Larsen.
Tesla’s lawyers focused on what is not stated in the warranty. They said,
The Tesla lithium-ion battery (the “Battery”) and Drive Unit are extremely sophisticated powertrain components designed to withstand extreme driving conditions. You can rest easy knowing that Tesla’s state-of-the-art Battery and Drive Unit are backed by this Battery and Drive Unit Limited Warranty.
In other words, the lawyers asserted that, although the warranty mentions the “Battery” and the “Drive Unit,” the legal language does not expressly identify the electric components that bind them together as part of an integral powertrain package.
They thus claimed that, the warranty covers components the High Voltage Unit and Rear Drive Unit but not the High Voltage Battery Service Panel which connects them together —despite its name:
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In other words, a legal decision excluded the PCS from being part of the battery and voiding it out of warranty. PCS is regarded as part of the electrical components.
There is no fix unless a class action suit can be put together.