Tesla Model S GEN1 Charger: Difference between revisions

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'''Unknown (HVJB Contactor Control?) Connector Xnnn'''


'''HVIL Connector Xnnn'''
'''HVIL Connector Xnnn'''


* 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 only if the OBC is the only or Master OBC.
* 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.


[[File:Tesla Model S Rear HVJB 06b.jpg|alt=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.|500x500px|thumb|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.]]
[[File:Tesla Model S Rear HVJB 06b.jpg|alt=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.|500x500px|thumb|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.]]
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* For Slave OBC, or all RAV4 EV, this connects to a short loopback instead.
* For Slave OBC, or all RAV4 EV, this connects to a short loopback harness instead.
[[File:Tesla Model S GEN1 OBC 018-1b.jpg|alt=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.|none|thumb|500x500px|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.]]
[[File:Tesla Model S GEN1 OBC 018-1b.jpg|alt=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.|none|thumb|500x500px|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.]]
'''Unknown (HVJB Contactor Control?)  Connector Xnnn'''
'''Unknown (HVJB Contactor Control?)  Connector Xnnn'''
'''Unknown (HVJB Contactor Control?) Connector Xnnn'''


==Common Issues==
==Common Issues==

Revision as of 04:49, 8 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.

The Tesla GEN1 on-board AC charger (OBC) is a single/three phase 10kW AC charger that was fitted originally and primarily in the Tesla Model S, from 2012 through late 2013, when it was replaced with GEN2. GEN1 models are easy to identify, having the word "TESLA" stamped on the top metalwork and no 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. If two are fitted, both are identical hardware, though the firmware differs.

The charger is made up of three 3.3 kw modules, each mounted to a liquid-cooled heat sink that forms the bottom plate/base. 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-Sep2013 Tesla Model S, 2012-14 (eg All) Toyota RAV4 EV[1], and 2014-17 MB B250e[2]. As far as is known, these are identical from a hardware perspective[3], 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

Logic Connector X042, 12-pin

The Logic Connector X042 needed to plug into the charger is Molex 19418-0026[4] which is in the MX150L series. This connector features CPA[5] (Connector Position Assurance), a dual-locking feature. For bench-testing, etc., the non-CPA connector is Molex 19418-0038[6]; 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[7]

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 (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

Tesla Model S GEN1 OBC Power Connectors

DC (Output) Connector Xnnn

The AC Input Connector housing needed to plug into the charger is Molex 42816-0412[8]

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


The female terminals for this housing are Molex 42815-0134[9] for 8 AWG (8mm²).

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


AC (Input) Connector Xnnn

The DC Output Connector housing needed to plug into the charger is Molex 42816-0312[10]

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

See above DC Output Connector above terminals; it uses the same female terminals.


HVIL Connector Xnnn

  • 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.
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.


Unknown (HVJB Contactor Control?) Connector Xnnn

Unknown (HVJB Contactor Control?) 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.
Tesla Model S GEN1 OBC, showing prominent Ground Strap
  • Two 50A fuses protect the AC input legs: for 1-ph version, 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 their fuses fail more than once. There are two, and 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[11]. Some people have found that after replacing a single failed fuse, the other one will later fail, so the generic recommendation is to replace them both. Typical pricing is USD$50-100 each in 2023.

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://www.molex.com/molex/products/part-detail/crimp_housings/0194180026
  5. ↑ https://www.molex.com/molex/products/family/mx150l_sealed_connector_system
  6. ↑ https://www.molex.com/molex/products/part-detail/crimp_housings/0194180038
  7. ↑ https://www.molex.com/molex/products/part-detail/crimp_terminals/0194200010
  8. ↑ https://www.molex.com/molex/products/part-detail/crimp_housings/0428160412
  9. ↑ https://www.molex.com/molex/products/part-detail/crimp_terminals/0428150134
  10. ↑ https://www.molex.com/molex/products/part-detail/crimp_housings/0428160312
  11. ↑ https://teslamotorsclub.com/tmc/posts/1899210/
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