Tesla Model S GEN1 Charger
Overview
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
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.
The female terminals for this housing are Molex 19420-0010[7]
| 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
DC (Output) Connector Xnnn
The AC Input Connector housing needed to plug into the charger is Molex 42816-0412[8]
The female terminals for this housing are Molex 42815-0134[9] for 8 AWG (8mm²).
AC (Input) Connector Xnnn
The DC Output Connector housing needed to plug into the charger is Molex 42816-0312[10]
See above DC Output Connector above terminals; it uses the same female terminals.
Unknown (HVJB Contactor Control?) 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.
- For Slave OBC, or all RAV4 EV, this connects to a short loopback instead.
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.
- 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
- ↑ 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.myrav4ev.com/forum/viewtopic.php?p=29981#p29981
- ↑ https://www.molex.com/molex/products/part-detail/crimp_housings/0194180026
- ↑ https://www.molex.com/molex/products/family/mx150l_sealed_connector_system
- ↑ https://www.molex.com/molex/products/part-detail/crimp_housings/0194180038
- ↑ 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
- ↑ https://teslamotorsclub.com/tmc/posts/1899210/