Tesla Model S GEN1 Rear HVJB: Difference between revisions

From openinverter.org wiki
Jump to navigation Jump to search
Line 51: Line 51:
*Tesla: The loopback harness, Tesla 1101371-00-A, is included/stored inside all Tesla Model S GEN1 Rear HVJB in an internal "parking" socket, when only a single OBC is provisioned.
*Tesla: The loopback harness, Tesla 1101371-00-A, is included/stored inside all Tesla Model S GEN1 Rear HVJB in an internal "parking" socket, when only a single OBC is provisioned.
===='''Fast Charge Contactors Control'''====
===='''Fast Charge Contactors Control'''====
*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.
*[[File:Tesla Model S Rear HVJB 04b.jpg|alt=Tesla Model S Rear HVJB: Single/Master OBC interface connectors.  All (5) of these are in use for the Single/Master OBC; only the AC and DC connectors are in use for a Second/Slave OBC (no HVIL or Fast Charge Connectors are used for the Second/Slave OBC).|thumb|600x600px|Tesla Model S Rear HVJB: Single/Master OBC interface connectors.  All (5) of these are in use for the Single/Master OBC; only the AC and DC connectors are in use for a Second/Slave OBC (no HVIL or Fast Charge Connectors are used for the Second/Slave OBC).]]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 Fast Charge contactors are Tesla 1006871-00-A (TE Connectivity 2138957-2), but no datasheet can be found.
*It is not known if the OBC performs PWM economizing.  The Rear HVJB Fast Charge 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).
*The top row pins are 12v; the bottom row pins are Auxiliary contacts, NO (normally open).

Revision as of 03:09, 24 March 2023

Tesla Model S GEN1 Rear HVJB
Tesla Model S GEN1 Rear HVJB

Overview

The Tesla Model S GEN1 Rear HVJB was a High Voltage Junction Box found in the all 2012 through late 2013 Model S. It is centrally located under the rear seat frame, and the Single or Dual GEN1 On-board Charger(s) (OBC) are located to the right and left of it. It was replaced via gradual phase-in by the GEN2 Rear HVJB starting around Oct2013, when the GEN2 On-board Chargers were introduced; the GEN1 & GEN2 Rear HVJBs are not interchangeable, physically nor electrically.

It functions as a junction for connections to these subsystems:

  • Traction Battery Pack (HV DC)
  • Drive Unit ("Inverter") (rear only, as the Dual Motor option wasn't offered during the GEN1's lifespan)
  • Charge Port (AC and DC input)
  • DC-DC Converter (GEN1, which also functioned as the Front HVJB)
  • On-Board Charger(s) (GEN1 Chargers only)


Tesla Model S Rear HVJB, cover removed.
Tesla Model S Rear HVJB, cover removed.

Connections

HV

All HV connections are well documented by the "Theory of Operation" image below. All are bolted connections.

Tesla Model S GEN1 Rear HVJB component details, from Tesla Service Manual, "Theory of Operation" section.
Tesla Model S GEN1 Rear HVJB component details, from Tesla Service Manual, "Theory of Operation" section.

LV

Depending upon whether Single or Dual OBCs are installed, either (1), or (5), of the LV connectors will not be in use. Extra/unused internal harnessed connectors have "parking" places to stow unused connectors. The various LV connectors are detailed below.

Logic "dummy" connector

This is a panel-mount Molex MX150L Panel-Mount PCB 19428-0001 plug. For installations where there is only a Single OBC installed, it provides a place to "park" the unused harness WWMA2 that would normally be connected to a Second/Slave OBC.

Tesla Model S OBC in Single/Master configuration. Note "parked" harness WWMA2 on Rear HVJB.
Tesla Model S OBC in Single/Master configuration.  Note "parked" harness WWMA2 on Rear HVJB.

It has a small PCB soldered to its rear, which contains ONLY (3) 180 ohm resistors, wired in parallel, to provide a net 60 ohm path for the HVIL Loop, on pins 3 & 9. See HVIL section for details on how this connector is used.


The following images showcase this "parking" connector on the Rear HVJB for harness WWMA2, which if not connected to a Second/Slave OBC, must be connected to this "parking" connector in order to obtain a 60 ohm resistor to complete the HVIL loop. The BMS maintains a constant current in the HVIL loop and measures the voltage drop associated with that current level. It will not allow the contactors to close (or remain closed) if the correct resistance isn't measured in the HVIL loop[1]. Telsa's various documentation from this era have several inaccuracies when verified against actual vehicles; do not rely upon documented pinouts.

Telsa Model S GEN1 Rear HVJB: harness WWMA2 "parking" connector which contains only a 60 ohm resistor. This connector is used when a Tesla does not have a Second/Slave OBC.
Telsa Model S GEN1 Rear HVJB: front view of harness WWMA2 "parking" connector which contains only a 60 ohm resistor.  This connector is used when a Tesla does not have a Second/Slave OBC.
Telsa Model S GEN1 Rear HVJB: rear views of harness WWMA2 "parking" connector which contains only a 60 ohm resistor.  This connector is used when a Tesla does not have a Second/Slave OBC.
Telsa Model S GEN1 Rear HVJB: rear view of harness WWMA2 "parking" connector which contains only a 60 ohm net resistance.  This connector is used when a Tesla does not have a Second/Slave OBC.
Tesla Model S GEN1 Rear HVJB "parking" connector for harness WWMA2, used in Single OBC installations only. Note (3) 180 ohm resistors, connected in parallel, to obtain net 60 ohms for HVIL loop.
Tesla Model S GEN1 Rear HVJB "parking" connector for harness WWMA2, used in Single OBC installations only.  Note (3) 180 ohm resistors, connected in parallel, to obtain net 60 ohms for HVIL loop.
180 ohm resistor. One of three on the Tesla Model S GEN1 Rear HVJB "parking" connector for harness WWMA2, which is used only in Single OBC installations.
180 ohm resistor. One of three on the Tesla Model S GEN1 Rear HVJB "parking" connector for harness WWMA2, which is used only in Single OBC installations.


HVIL

The HVIL Loop

Telsa Model S GEN1 HVIL Schematic (amended).
Telsa Model S GEN1 HVIL Schematic (amended): shows the lid switches explicitly called out, and the "parked" vs "installed" HVIL Loopback on Second/Slave OBC.

Like other HV assemblies on the Model S, the Rear HVJB has a Lid Reed Switch, activated by a magnet on the cover, that breaks the HVIL Loop when the cover is removed. The Rear HVJB has a short harness from this Lid Reed Switch, which is always plugged into the Single or Master OBC to maintain the HVIL Loop.

HVIL Lid Reed Switch

The below two pictures show the GEN1 Rear HVJB's Lid Reed Switch, which had a relatively high failure rate[2] that caused shutdowns, error messages, and start failures:

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 Rear HVJB (under rear seat), lid removed, showing the HVIL cover reed switch and HVIL connector that connects to a mating connector on the 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 HVIL circuit overview, from Tesla Service Bulletin SB-10052449-4313, pg. 1.
Tesla Model S GEN1 HVIL circuit overview, from Tesla Service Bulletin SB-10052449-4313, pg. 1.
Tesla Model S GEN1 HVIL circuit overview, from Tesla Service Bulletin SB-10052449-4313, pg. 7.
Tesla Model S GEN1 HVIL circuit overview, from Tesla Service Bulletin SB-10052449-4313, pg. 8.


HVIL Loopback Harness
  • Tesla: The loopback harness, Tesla 1101371-00-A, is included/stored inside all Tesla Model S GEN1 Rear HVJB in an internal "parking" socket, when only a single OBC is provisioned.

Fast Charge Contactors Control

  • Tesla Model S Rear HVJB: Single/Master OBC interface connectors. All (5) of these are in use for the Single/Master OBC; only the AC and DC connectors are in use for a Second/Slave OBC (no HVIL or Fast Charge Connectors are used for the Second/Slave OBC).
    Tesla Model S Rear HVJB: Single/Master OBC interface connectors.  All (5) of these are in use for the Single/Master OBC; only the AC and DC connectors are in use for a Second/Slave OBC (no HVIL or Fast Charge Connectors are used for the Second/Slave OBC).
    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 Fast Charge 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).

AC Input Connector

The Power Input/Output connectors are of the Molex Mini-Fit Sr. wire-to-wire series[3]. The datasheet is here.

The AC Input Connector housing included, to plug into the OBC, is Molex 42816-0312[4]

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

DC Output Connector

The DC Output Connector housing included, to plug into the OBC, is Molex 42816-0412[5]

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


The female terminals for the Power Input/Output housings are Molex 42815-0134[6] 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[7].

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


Errata

GEN1 Rear HVJB Dimensions:

  • Weight: nn lbs (nn kg)

Tesla Part Numbers (TPN):

  • 1016561
  1. ↑ https://static.nhtsa.gov/odi/tsbs/2014/SB-10052449-4313.pdf Pg. 1
  2. ↑ https://static.nhtsa.gov/odi/tsbs/2014/SB-10052449-4313.pdf Pg. 10
  3. ↑ https://www.molex.com/molex/products/family/minifit_sr
  4. ↑ https://www.molex.com/molex/products/part-detail/crimp_housings/0428160312
  5. ↑ https://www.molex.com/molex/products/part-detail/crimp_housings/0428160412
  6. ↑ https://www.molex.com/molex/products/part-detail/crimp_terminals/0428150134
  7. ↑ https://www.mouser.com/datasheet/2/276/0428150031_CRIMP_TERMINALS-1373081.pdf
Retrieved from "https://openinverter.org/wiki/index.php?title=Tesla_Model_S_GEN1_Rear_HVJB&oldid=3638"