Tesla Model S GEN1 Charger: Difference between revisions

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==== '''HVIL Connector (J5)''' ====
==== '''HVIL Connector (J5)''' ====
[[File:Tesla Model S GEN1 OBC 036b.jpg|alt=Tesla Model S GEN1 OBC: HVIL and HVJB AC Charging Bypass Contactor Control Connectors|thumb|600x600px|Tesla Model S GEN1 OBC: HVIL and HVJB AC Charging Bypass Contactor Control Connectors|none]]
[[File:Tesla Model S GEN1 OBC 036b.jpg|alt=Tesla Model S GEN1 OBC: HVIL and HVJB AC Charging Bypass Contactor Control Connectors|thumb|600x600px|Tesla Model S GEN1 OBC: HVIL and HVJB AC Charging Bypass Contactor Control Connectors]]
[[File:2012 ModelS LHD Release 24.2-3b.png|alt=Telsa Model S GEN1 HVIL Schematic (amended).|center|thumb|600x600px|Telsa Model S GEN1 HVIL Schematic (amended).]]
[[File:2012 ModelS LHD Release 24.2-3b.png|alt=Telsa Model S GEN1 HVIL Schematic (amended).|thumb|600x600px|Telsa Model S GEN1 HVIL Schematic (amended).|none]]
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Revision as of 17:34, 22 March 2023

Overview

Tesla GEN1 Onboard AC Charger
Tesla GEN1 Onboard AC Charger. Note the stamped "TESLA" on the cover, which visually distinguishes it from later versions. This view shows the Logic Connector X042/X043

The Tesla GEN1 on-board AC charger (OBC) was a single phase 10kW AC charger that was fitted originally and primarily in the Tesla Model S, from Jun2012 through late2013*, when it was replaced with GEN2. GEN1 models are easy to identify, having the word "TESLA" stamped on the top metalwork and having no black anti-tamper tape; the GEN2 charger lacks the Tesla identifier stamped on the metalwork, and has anti-tamper tape over the seams.

One (or optionally two, in a Master/Slave configuration) GEN1 chargers are installed beneath the rear seats in the Model S for AC charging. The Single/Master OBC is on the right side of center. If two OBCs are fitted, the Second/Slave is fitted to the left of center under the rear seat; both are identical hardware, though the firmware differs.

The charger is comprised of (three 3.3 kw modules?), each mounted to a liquid-cooled heat sink that forms the base. This assembly enables single phase AC charging only.

The GEN1 chargers are considered to be more trouble-prone than the later units, and are not as popular for use in EV conversions or ground-up builds, partly because they do not support 3-phase AC input. However, they are used in many OEM installations that continue to need servicing. Examples of OEM installs include Telsa (all 2012-Sep2013 Model S), Toyota (all 2012-14 RAV4 EV[1]), and Mercedes-Benz (all 2014-17 B250e[2]). As far as is known, these are identical from a hardware perspective[3], but the firmware differs and is not interchangeable between installations.


* The GEN2 OBCs were apparently phased in gradually. There are reports of Dec2013 with GEN1 OBCs[4], and Oct2013 with GEN2 OBCs[5][6].

Charger Connectors

Overview

There are six discrete connectors on the GEN1 OBC.

Tesla Model S GEN1 OBC Connectors
Tesla Model S GEN1 OBC Connectors
  • Logic (X042 (or X043, when used in "Slave" mode))
  • AC (Input)
  • DC (Output)
  • HVIL (High Voltage InterLock)
  • AC Charging Bypass Contactors Control (2x)


In some applications, not all six connectors may be in use:

  • Tesla: In Single OBC vehicles, all connectors are used. This is the most common scenario.
  • Tesla: In Dual OBC vehicles, the second ("Slave") OBC does not utilize the AC Charging Bypass connectors, as the first ("Master") OBC performs the function.
  • Toyota: The AC Charging Bypass connectors are not used, as the vehicle is not provisioned for DCFC and therefore there are no AC Charging Bypass contactors.
  • Mercedes-Benz: TBD (probably same as Toyota).

Logic Connector (X042 or X043)

Tesla Model S GEN1 OBC X042 Logic Connector pinout.
Tesla Model S GEN1 OBC X042 Logic Connector pinout.

For Logic Connector X042 (X043, when referred to when provisioned in "Slave" duty), the mating connector needed to plug into the charger is Molex 19418-0026[7] for 18-22 AWG (19418-0027 for 14-16 AWG) which is in the MX150L series. This connector features CPA[8] (Connector Position Assurance), a dual-locking feature. For bench-testing, etc., the non-CPA connector is Molex 19418-0038[9] for 18-22 AWG (19418-0037 for 14-16 AWG); this connector requires one less operation to disengage, but is less suitable for automotive use or environments where heavy vibration is present.

Telsa Model S (2012-2013) OBC Logic Connector X042 details, from Tesla Service Manual.
Logic Connector X042 (Master charger) and X043 (Slave charger). Molex 19418-0026, female harness connector to mate with X042 Logic Connector on Tesla GEN1 OBC.
Logic Connector X042, Master charger, and X043, Slave charger. Molex 19418-0026, female connector to mate with X042 Logic Connector on Tesla GEN1 OBC.
Molex 19418-0026, female harness-side connector to mate with X042 (male terminals) Logic Connector on Tesla GEN1 OBC (Logic Connector X042 (Master charger) and X043 (Slave charger)). This is the terminals-end view of the housing.


The female terminals for this housing are Molex 19420-0010[10] (18-22 AWG; 19420-0009 for 14-16 AWG). These are tin-plated, and are rated for (25) cycles. Gold-plated versions are available, and they are rated for (100) cycles.

Molex 19420-0010 female terminals for Logic Connector X042, for 18-22 AWG (0.35-0.75mm²).

Logic Connector X042
Pin No. Function Description Tesla

Wire size *

Telsa

Wire Color *

1 12v supply 18 AWG (0.75mm²) RD-BR
2 Charge Port: nozzle lock "InsertEN out" 20 AWG (0.5mm²) YL
3 HVIL Out 20 AWG (0.5mm²) YL-RD
4 CAN + 20 AWG (0.5mm²) RD
5 EVSE-Pilot (CP) 20 AWG (0.5mm²) PU
6 FC CAN AKA "FC_CAN". Possibly SWCAN. Connects only to BMS "FC_CAN+" 20 AWG (0.5mm²) RD-WH
7 12v GND 20 AWG (0.5mm²) BK
8 Drive inhibit "Prox out", signal to DU to inhibit drive 22 AWG (0.35mm²) OR-PU
9 HVIL In 20 AWG (0.5mm²) YL-BR
10 CAN - 20 AWG (0.5mm²) DB
11 EVSE-Prox (PP) 20 AWG (0.5mm²) OR
12 "BMS_12V_in" "Cont_PWR (out)" (Contactor power?) from BMS (BMS enables charger?) 18 AWG (0.75mm²) RD-GY

* = Specifications are from 2012 Tesla Model S documentation; other applications may have differing specs.


When an OBC is provisioned as a Second OBC ("Slave"), the Logic connector is populated with a subset of the above, as the First OBC ("Master") handles all external interfaces. Only power/GND, CAN, and HVIL are connected.

Tesla GEN1 OBC: "Slave" configuration Logic and HVIL connections.
Tesla GEN1 OBC: "Slave" configuration Logic and HVIL connections.
Tesla GEN1 OBC: "Slave" configuration Logic and HVIL connections.
Tesla GEN1 OBC: "Slave" configuration Logic and HVIL connections.

AC Input Connector

The Power Input/Output connectors are of the Molex Mini-Fit Sr. wire-to-wire series[11]. The datasheet is here.

The AC Input Connector housing needed to plug into the charger is Molex 42816-0312[12]

Molex 42816-0312 housing, 3P, for DC Output.

DC Output Connector

The DC Output Connector housing needed to plug into the charger is Molex 42816-0412[13]

Molex 42816-0412 housing, 4P, for AC Input.


The female terminals for the Power Input/Output housings are Molex 42815-0134[14] for 8 AWG (8mm²). The Molex datasheet strongly recommends the use of Nylogel 760G dielectric grease on this terminal if it will be exposed to vibration and/or thermal cycling[15].

Molex 42815-0134 female terminal, for 8AWG (8mm²) wire.



HVIL Connector (J5)

Tesla Model S GEN1 OBC: HVIL and HVJB AC Charging Bypass Contactor Control Connectors
Tesla Model S GEN1 OBC: HVIL and HVJB AC Charging Bypass Contactor Control Connectors
Telsa Model S GEN1 HVIL Schematic (amended).
Telsa Model S GEN1 HVIL Schematic (amended).
  • J5 HVIL: Only the outside pins are in use. These are used to integrate the HVJB's Lid Reed Switch into the HVIL loop, and this is connected to the HVJB's Lid Reed Switch if the OBC is the only (single) or Master (dual) OBC.
Closeup of Tesla Model S GEN1 HVJB (under rear seat), lid removed, showing the HVIL cover reed switch and HVIL connector that connects to a mating connector on the OBC.
Tesla Model S GEN1 HVJB (under rear seat), lid removed, showing the HVIL cover reed switch and HVIL connector that connects to a mating connector on the OBC.
Tesla Model S GEN1 HVJB (under rear seat), lid removed, showing the HVIL cover reed switch and HVIL connector that connects to a mating connector on the OBC.
Tesla Model S GEN1 HVJB (under rear seat), lid removed, showing the HVIL cover reed switch and HVIL connector that connects to a mating connector on the OBC.


  • For Slave OBC, or all RAV4 EV, this connects to a short loopback harness instead. The loopback harness, Tesla 1101371-00-A, is included inside all Tesla Model S GEN1 Rear HVJB in a "parking" connector, when only a single OBC is provisioned.
Tesla Model S GEN1 OBC HVIL Loopback connector. Used on Tesla Slave OBC installations where the HVJB Lid Reed Switch is already connected to the HVIL circuit via the Master OBC. Also used in RAV4 EV, as there is no HVJB installed at all in those models.
Tesla Model S GEN1 OBC HVIL Loopback connector.  Used on Tesla Slave OBC installations where the HVJB Lid Reed Switch is already connected to the HVIL circuit via the Master OBC.  Also used in RAV4 EV, as there is no HVJB installed at all in those models.

AC Charging Bypass Contactors Control (J1 & J3)

  • These four-pin connectors each drive a single contactor in the Rear HVJB. Those contactors bypass AC charging and allow DC from the Charge Port to connect directly to the HV bus for DCFC.
  • It is not known if the OBC performs PWM economizing. The Rear HVJB AC Bypass contactors are Tesla 1006871-00-A (TE Connectivity 2138957-2), but no datasheet can be found.
  • The top row pins are 12v; the bottom row pins are Auxiliary contacts, NO (normally open).
  • These connectors are not used in the Toyota RAV4 EV (and possibly not used in MB B250e) as the RAV4 EV is not provisioned for DCFC and does not have those contactors.

Common Issues

  • The Tesla chargers are very sensitive to grounding. The case MUST be connected to vehicle 12v ground and EVSE earth/ground when charging. [1] The OEM installation for the Tesla Model S has a prominent ground strap.
Tesla Model S GEN1 OBC, showing prominent Ground Strap
  • Two 50A fuses protect the AC input legs: one fuse for Neutral, one for Hot/L1. These fuses are a common failure point. The cause of their failure is not known. Some units have had their fuses fail more than once. Typically, only one fails at a time. The fuses are "semiconductor fuses", special high-speed parts (opposite of "slow-blow") for use with sensitive electronics, and they sometimes have a hybrid diode-and-fuse symbol, though they have no diode function. The OEM fuse is Ferraz Shawmut 50A 500VAC fuse, part No. A50P50-4[16]. Some people have found that after replacing a single failed fuse, the other one will later fail; it is surmised that this is possibly a genuine instance of a fuse weakening over time/use, so the generic recommendation is to replace them both. Typical pricing is USD$50-100 each in 2023.

Important Considerations

Output Voltage Range

Tesla GEN1 OBC label, showing part No. and input/output specs. These are not to be relied upon.
Tesla GEN1 OBC label, showing part No. and input/output specs.  These are not to be relied upon.
HEED DAMIEN'S WARNING:[17]

"Running a Tesla charger at much under 200v dc will cause it to explode. Yes I know the label says 50 to 450v but it lies. Yes I blew one up discovering this."

Errata

Charger Dimensions:

  • nnnmm x nnnmm x nnnmm
  • Weight: 42 lbs (19 kg)

Tesla Part Numbers (TPN):

  • 6009278-00-x
  • 6009278-84-x (ReManufactured + Slave?)
  • 6009354-00-x

Toyota Part Numbers:

  • G9090-0R010 (discontinued)
  • G9090-0R011

MB Part Number(s):

  • TBD

Notes

  1. ↑ https://en.wikipedia.org/wiki/Toyota_RAV4_EV#Second_generation_(2012)
  2. ↑ https://en.wikipedia.org/wiki/Mercedes-Benz_B-Class#B-Class_Electric_Drive
  3. ↑ https://www.myrav4ev.com/forum/viewtopic.php?p=29981#p29981
  4. ↑ https://youtu.be/yPOtAotzvTY?t=16
  5. ↑ https://teslamotorsclub.com/tmc/posts/6516611
  6. ↑ https://teslamotorsclub.com/tmc/posts/3042384
  7. ↑ https://www.molex.com/molex/products/part-detail/crimp_housings/0194180026
  8. ↑ https://www.molex.com/molex/products/family/mx150l_sealed_connector_system
  9. ↑ https://www.molex.com/molex/products/part-detail/crimp_housings/0194180038
  10. ↑ https://www.molex.com/molex/products/part-detail/crimp_terminals/0194200010
  11. ↑ https://www.molex.com/molex/products/family/minifit_sr
  12. ↑ https://www.molex.com/molex/products/part-detail/crimp_housings/0428160312
  13. ↑ https://www.molex.com/molex/products/part-detail/crimp_housings/0428160412
  14. ↑ https://www.molex.com/molex/products/part-detail/crimp_terminals/0428150134
  15. ↑ https://www.mouser.com/datasheet/2/276/0428150031_CRIMP_TERMINALS-1373081.pdf
  16. ↑ https://teslamotorsclub.com/tmc/posts/1899210/
  17. ↑ https://openinverter.org/forum/viewtopic.php?p=9994#p9994
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