Tesla Model S GEN1 Charger: Difference between revisions
| Line 27: | Line 27: | ||
!Function | !Function | ||
!Description | !Description | ||
!Wire size * | !Wire size * | ||
!Wire Color* | !Wire Color * | ||
|- | |- | ||
|1 | |1 | ||
|12v supply | |12v supply | ||
| | | | ||
|18 AWG (0.75mm²) | |18 AWG (0.75mm²) | ||
|RD/BR | |RD/BR | ||
|- | |- | ||
| Line 39: | Line 39: | ||
|Charge Port: nozzle lock | |Charge Port: nozzle lock | ||
|"InsertEN out" | |"InsertEN out" | ||
|20 AWG (0.5mm²) | |20 AWG (0.5mm²) | ||
|YL | |YL | ||
|- | |- | ||
| Line 45: | Line 45: | ||
|HVIL Out | |HVIL Out | ||
| | | | ||
|20 AWG (0.5mm²) | |20 AWG (0.5mm²) | ||
|YL/RD | |YL/RD | ||
|- | |- | ||
| Line 51: | Line 51: | ||
|CAN + | |CAN + | ||
| | | | ||
|20 AWG (0.5mm²) | |20 AWG (0.5mm²) | ||
|RD | |RD | ||
|- | |- | ||
| Line 57: | Line 57: | ||
|EVSE-Pilot (CP) | |EVSE-Pilot (CP) | ||
| | | | ||
|20 AWG (0.5mm²) | |20 AWG (0.5mm²) | ||
|PU | |PU | ||
|- | |- | ||
| Line 63: | Line 63: | ||
|FC CAN (SWCAN?) | |FC CAN (SWCAN?) | ||
| | | | ||
|20 AWG (0.5mm²) | |20 AWG (0.5mm²) | ||
|RD/WH | |RD/WH | ||
|- | |- | ||
| Line 69: | Line 69: | ||
|12v GND | |12v GND | ||
| | | | ||
|20 AWG (0.5mm²) | |20 AWG (0.5mm²) | ||
|BK | |BK | ||
|- | |- | ||
| Line 75: | Line 75: | ||
|Drive inhibit | |Drive inhibit | ||
|"Prox out", signal to DU to inhibit drive | |"Prox out", signal to DU to inhibit drive | ||
|22 AWG (0.35mm²) | |22 AWG (0.35mm²) | ||
|OR/PU | |OR/PU | ||
|- | |- | ||
| Line 81: | Line 81: | ||
|HVIL In | |HVIL In | ||
| | | | ||
|20 AWG (0.5mm²) | |20 AWG (0.5mm²) | ||
|YL/BR | |YL/BR | ||
|- | |- | ||
| Line 87: | Line 87: | ||
|CAN - | |CAN - | ||
| | | | ||
|20 AWG (0.5mm²) | |20 AWG (0.5mm²) | ||
|DB | |DB | ||
|- | |- | ||
| Line 93: | Line 93: | ||
|EVSE-Prox (PP) | |EVSE-Prox (PP) | ||
| | | | ||
|20 AWG (0.5mm²) | |20 AWG (0.5mm²) | ||
|OR | |OR | ||
|- | |- | ||
| Line 99: | Line 99: | ||
|"BMS_12V_in" | |"BMS_12V_in" | ||
|(BMS enables charger?) | |(BMS enables charger?) | ||
|18 AWG (0.75mm²) | |18 AWG (0.75mm²) | ||
|RD/GY | |RD/GY | ||
|} | |} | ||
]] | ]] | ||
<nowiki>*</nowiki> = Specifications from 2012 Tesla Model S documentation; other applications may have differing specs. | <nowiki>*</nowiki> = Specifications are from 2012 Tesla Model S documentation; other applications may have differing specs. | ||
'''Input/Output Connectors''' | '''Input/Output Connectors''' | ||
Revision as of 19:33, 25 February 2023
Overview
The Tesla GEN1 charger is a single/three phase 10kW AC charger that was fitted in the Model S from 2012 through late 2013, when it was replaced with GEN2. GEN1 models are easy to identify, with the word "TESLA" stamped on the metalwork; the GEN2 charger lacks the Tesla identifier stamped on the metalwork.
One (or optionally two, in a Master/Slave configuration) GEN1 chargers are installed beneath the rear seats in the Model S for AC charging. If two are fitted, both are identical hardware, though the firmware differs.
The charger is made up of three 3.3 kw modules, each sitting on a liquid cooling plate. This assembly enables both single and multi phase AC charging.
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, but are used in many OEM installations that continue to need servicing. Examples of OEM installs include the 2012-13 Tesla Model S, 2012-14 Toyota RAV4 EV[1], and 2014-17 MB B250e[2]. As far as is known, these are identical from a hardware perspective, but the firmware does differ and is not interchangeable between installations.
Connectors
Charger Connections
There are six discrete connectors on the GEN1 OBC. In typical applications, they are not all in use.
Logic Connector X042
The Logic Connector X042 needed to plug into the charger is Molex 19418-0026[3] which is in the MX150L series.
The female terminals for this housing are Molex 19420-0010[4]
| Pin No. | Function | Description | Wire size * | 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 (SWCAN?) | 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" | (BMS enables charger?) | 18 AWG (0.75mm²) | RD/GY |
* = Specifications are from 2012 Tesla Model S documentation; other applications may have differing specs.
Input/Output Connectors
AC (Input) Connector Xnnn
The AC Input Connector housing needed to plug into the charger is Molex 42816-0412[5]
The female terminals for this housing are Molex 42815-0134[6] for 8 AWG (8mm²).
DC (Output) Connector Xnnn
The DC Output Connector housing needed to plug into the charger is Molex 42816-0312[7]
See above AC Input Connector for terminals reference.
Unknown Connector Xnnn
Unknown Connector Xnnn
Unknown Connector Xnnn
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.
Errata
Charger Dimensions:
- nnnmm x nnnmm x nnnmm
- Weight: nn lbs (nn kg)
Tesla Part Numbers (TPN)
- 6009278-00-x
Notes
- ↑ https://en.wikipedia.org/wiki/Toyota_RAV4_EV#Second_generation_(2012)
- ↑ https://en.wikipedia.org/wiki/Mercedes-Benz_B-Class#B-Class_Electric_Drive
- ↑ https://www.molex.com/molex/products/part-detail/crimp_housings/0194180026
- ↑ https://www.molex.com/molex/products/part-detail/crimp_terminals/0194200010
- ↑ https://www.molex.com/molex/products/part-detail/crimp_housings/0428160412
- ↑ https://www.molex.com/molex/products/part-detail/crimp_terminals/0428150134
- ↑ https://www.molex.com/molex/products/part-detail/crimp_housings/0428160312