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; 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[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.
The female terminals for this housing are Molex 19420-0010[5]
| 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[6]
The female terminals for this housing are Molex 42815-0134[7] for 8 AWG (8mm²).
DC (Output) Connector Xnnn
The DC Output Connector housing needed to plug into the charger is Molex 42816-0312[8]
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.
- Fuses
The two fuses (AC? DC?) are commonly found to fail. The cause 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 special high-speed units for use with sensitive electronics.
Errata
Charger Dimensions:
- nnnmm x nnnmm x nnnmm
- Weight: nn lbs (nn kg)
Tesla Part Numbers (TPN)
- 6009278-00-x
Toyota Part Numbers:
- G9090-0R010 (discontinued)
- G9090-0R011
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/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