Tesla Charger Support Thread

[janosch]

I have seen photos from the wreck, yes we currently think either firemen's waterhose, or storage afterwards.

Question remains if someone has `fully` opened the charger yet? Because if the board just got wet and wasn't turned on, drying it thoroughly should make it come back to life

[EV_Builder]

Fully not because that's quite a job! Many parts are glued in.
I would just let it dry and cross the fingers.
Must say that big chance it will work because of the amounts of glue/gummy filler and lacquer used.

I only would open it and resettle connectors etc. So you are sure connections are proper.

[EV_Builder]

We got two gen 2 chargers and opened them today.

Turns out one of them was WET on the inside. Not water from the cooling outlets, definitely from within the unit.

We could now either
1) try drying it as good as we can and then check if it works
2) disassemble it further, to see where & how the water got in.

Has someone taken the actual charger boards out before? They seem glued in.

I will press on with the other charger for now, that seems dry at least.

A charger:
PXL_20210423_113704320.jpg

A picture of water on a table:
PXL_20210423_113600198.jpg

Sealant on the inside liquifying itself:
PXL_20210423_152746917.MP.jpg

Corrosion?
PXL_20210423_145708655.jpg

Suspicious connector:
PXL_20210423_160129936.jpg

Could you tell me the partnumber of your charger?
And the partnumber of the two boards?
The phase board and the smaller board (in de top corner) which you removed/replaced?

[EV_Builder]

Can anyone publish there hardware numbers/versions?
Just to check if those are the same albeit the cover has a different number?

(1014963-05-B spcharger POS#2)
- Controlboard Tesla : 1026865-00-D REV02
- Charge module : (1026696-00-G)
- Molex Side Print version: (1020419-01-C REV3)
- Board Cable Part Nr: (1017601-00-B)

Can someone please check and report back what their numbers are?

[janosch]

Can anyone publish there hardware numbers/versions?
Just to check if those are the same albeit the cover has a different number?

(1014963-05-B spcharger POS#2)
- Controlboard Tesla : 1026865-00-D REV02
- Charge module : (1026696-00-G)
- Molex Side Print version: (1020419-01-C REV3)
- Board Cable Part Nr: (1017601-00-B)

Can someone please check and report back what their numbers are?

Sure,

on the logic boards we removed it says:
FAB1017502-00-E CDS 4/13 REV-01

On the outside the label says:
ASY, GEN 2 CHRGR, MDLS,
TPN: 1014963-00-K
TSN: T15G0141436

Hope that helps.

Haven't plugged it in yet with the new firmware, going to do that literally today or tomorrow morning.


Oh, by the way, does someone have a part number/vendor for CONN1 on the logic board?

[EV_Builder]

Can anyone publish there hardware numbers/versions?
Just to check if those are the same albeit the cover has a different number?

(1014963-05-B spcharger POS#2)
- Controlboard Tesla : 1026865-00-D REV02
- Charge module : (1026696-00-G)
- Molex Side Print version: (1020419-01-C REV3)
- Board Cable Part Nr: (1017601-00-B)

Can someone please check and report back what their numbers are?

Sure,

on the logic boards we removed it says:
FAB1017502-00-E CDS 4/13 REV-01

On the outside the label says:
ASY, GEN 2 CHRGR, MDLS,
TPN: 1014963-00-K
TSN: T15G0141436

Hope that helps.

Haven't plugged it in yet with the new firmware, going to do that literally today or tomorrow morning.


Oh, by the way, does someone have a part number/vendor for CONN1 on the logic board?

Ok that's a start, can you also tell me looking trough the plastic skin close to the white plastic what those partnumbers are?
Those are the 3 charge modules (one per phase itself). I'm very interested in those numbers too.

CONN1: well i couldn't find out either but i managed to harvest it from the Tesla board. If you have a SMD heating gun, soldering iron, solder wick and flux you can remove it.

I did it as follows:
- first remove the solder from the side spots to the PCB (Solder Wick) works perfect here...
- apply a tiny bit of force with a flat screwdriver starting at one side and heating that side with the hot air gun;
(move the heat all the time between all the legs but just pause 1 second extra on the side you started).
- after a short while one side will like start to pop a bit then it becomes very easy just heat the closest pins and move the gun towards the end and all will pop loose. You can hear them pop. Offcourse apply a tiny bit of force it are small leads and you can flex them but don't want to bend them.

To solder it back i used flux and solder wick. Think i copied from damien. Basicly apply flux and solder it in and afterwards remove it again with Solder Wick.

Then before powering up check all leads for shorts.

The resin / coat is a pain but with a sharp knife and eventually some heat it will give up.

[janosch]

on the phase boards itself it says:
1026696-00F REV01
0315FF0004735

Yes, de-soldering conn1 worked, but I was wondering if I can order a few spare ones as I have more PCBs that I could pre-populate.

[EV_Builder]

on the phase boards itself it says:
1026696-00F REV01
0315FF0004735

Yes, de-soldering conn1 worked, but I was wondering if I can order a few spare ones as I have more PCBs that I could pre-populate.

Ok maybe Damien jumps in with the partnumber of the JST connector.

Last request: can you give me also the partnumber of the wiring loom inside the charger? The number is on the small label near said JST connector. (CONN1).

Thank u!

[Jack Bauer]

Connector part numbers are on the v1 board bom

[EV_Builder]

Ahhh offcourse. I could have came up myself with it.
Ok, i looked it up for us:

CONN1
- MFG/MPN : SM24B-CPTK-1A-TB(L);
- MOUSER PART : 306-SM24B-CPTK-1ATBL

Guess what:

Availability
Stock:
0
On Order:
797Expected 02/07/2021
1.170Expected 17/09/2021

[janosch]

Connector part numbers are on the v1 board bom

Perfect, thanks.

And on a separate note: I was able to run the charger today. It was a fun journey and I learned a lot on the way to get it working.

A remaining problem: on the A/C side it rises from 0A to 30A, then the EVSE fails out, and the process starts again, every 15s.
I am using commercial firmware.

variables:
idclim 45A, iaclim 16A, idcspnt 7A

I would have expected iaclim or idcspnt to kick in.

[ev340]

Trying and failing to find a Gen3 (v3) pinout for the 12 and 20 way plugs.
Also the pn for the ecu style shroud... (oops was at the bottom of the BOM... 100% Mybad!)

Can anyone point me in the right direction please? I read elsewhere in this thread that Patreon would contain the design files but I cannot find Gen3 anywhere.

[Boxster EV]

https://github.com/damienmaguire/Tesla-Gen3-Charger

[ev340]

https://github.com/damienmaguire/Tesla-Gen3-Charger

Thanks but that has the pinout for v1 and 2.
Which appear to be different to v3 and there is no pinout in the v3 folder.

The board schematics for the 20way plug have 12 traces for v1/2 but the schematic shows 11 for the v3.
I’m not confident enough to try to figure out what is what.

Edit:
So to avoid spamming the thread I’ll edit this post with the knowledge I’ve managed to scrape together, hopefully if I get anything wrong someone can point it out. And it might be helpful for the next guy?

The 20 way connector on v3 has traces to 12 and 13 removed because the USB port has been removed, so that makes sense, but the pinout also lists 5v+ To pin 14 which isn’t on the diagram And something I think I am misunderstanding?

More pertinently v3 diagram has a trace on pin 20 which goes to vss1 on the STM32, so is that a 3v line? To activate the board?

[Jack Bauer]

The pinout of the Gen3 charger controller is the same across all version that use the ME MX header :
https://github.com/damienmaguire/Tesla- ... Pinout.pdf

[Jack Bauer]

Just a note to folks who will be receiving Gen2 charger kits. Due to the ongoing component shortages I am using a slightly different connector header. It has one pin missing so must be fitted in the orientation shown. In this case the missing pin is unused so has no effect on operation.

[ev340]

The pinout of the Gen3 charger controller is the same across all version that use the ME MX header :
https://github.com/damienmaguire/Tesla- ... Pinout.pdf

Thank you for confirming.

Can I ask what pin 20 is for on the V3 board? As it has a trace but isn’t listed on the pinout?

I can see it goes to a voltage pin but I cannot understand the Purpose or a possible function that could serve?

[Jack Bauer]

Its an extra analog input for possible future use. Unimplemented in current software.

[ev340]

Its an extra analog input for possible future use. Unimplemented in current software.

Exciting prospects!
Thank you for clarifying!

[johu]

Any ideas for it?

[Jack Bauer]

No ideas at the minute
On another topic a customer recently had a problem with CAN communications on a Gen 2 board caused by not having soldered the can termination jumper under the wifi module. I asked that he update the thread and wiki but as that has not happened I'm doing so. If you intend to just use the board stand alone (most cases) the jumper should be soldered. As of this date any kits ordered will have this jumper soldered by default to avoid any further issues.

[EV_Builder]

IMHO we should make a dual CAN channel version. One inside world and one outside world. That way no collisions with ID's etc.

Another option/idea is to use one channel on the VCU together with the BMS and the drive train. The other VCU channel would be to the car and the third VCU would be for some aftermarket extra dash.

[Johaljaswant]

I am using Tesla Gen2 charger with Damien logic board and also using Tesla EVSE wall charger gen2.
When I give power to Tesla charger instantly the Tesla EVSE wall charger fuse blow up.
Firmware showing no fault.
What could be the reason.

[jon volk]

A fuse blowing up immediately sounds like a wiring short circuit somewhere. How many amps is said fuse?

[Johaljaswant]

Thanks for reply
Fuse is 160 Amp
Part no 160 LET