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We have had an incredibly tough time getting Gen2 chargers to work successfully and have probably amassed the larger private collection of Gen2 chargers in the world.

After getting another batch of 4 chargers (luckily for next to nothing) that didn't work, we realized that the chargers were from a scrapped Tesla Supercharger, 1014963-05-B. It appears that Tesla scrapped a bunch of V2 Superchargers last year and that a number found their way onto the market. Notice the description after the part number

After looking back at our past list of chargers, I realize that our last 2 Ebay purchases were also from Superchargers ,(but were being sold as out of actual Model S vehicles). There are still some being sold on Ebay. I have contacted the individuals and asked them to remove, or revise their ads. I quickly went through the support forum and see that some others that were having problems also had these same units.

Bryson provided some info on part numbers in the past that says that all -05- units won't work: Here's our list of chargers (excluding the last 4 bad chargers) with part numbers: As you can see, we had one Rev E charger that worked, and one Rev E that worked.

I have combed through the forum posts and see evidence of Rev J,K,G,L chargers working. All Gen3 chargers also appear to work (which would be the equivalent of a later Rev).

So, my guess is that early Gen2 chargers do not work. The change over was probably somewhere in the Rev E release. If anybody is buying a charger, at this time I would stick to Rev F or later. It would be helpful if others could post the REV of their unit and whether it worked or not.

Thanks for doing the research into this and posting.

This should be a STICKY at the top of the Tesla Forum Topic!
Mods?

Some of the Supercharger units are Rev C - and they don't work.

Purchased two Rev K chargers - and they both work! We will now be up to 27kW of charging capacity for our next race!

I unfortunately paid $250 for a super charger version from ebay before seeing this. Using the v5 board I am getting 125VDC from each module.

dougyip wrote: ↑Thu Sep 03, 2020 3:36 pm Some of the Supercharger units are Rev C - and they don't work.

Purchased two Rev K chargers - and they both work! We will now be up to 27kW of charging capacity for our next race!

Curious, do they not work because they are super charger scrap or because of the rev C? I have a local seller with a rev c from a model s I was looking at buying for a pretty good price.

Crazy thought but how about working out the differences in the CAN messaging and getting these chargers working then submitting the software on github? Lots of engineers on fiverr.com if you lack the skills.

I assume that the Supercharger units floating around are still functional - in their intended role. It's just that they won't work as onboard chargers as we want them to. I'm not sure if the problem is specific to Supercharger units, or just any early (Pre Rev E?) unit.

Damien: Tom has looked at some of our CAN logs from a non-working unit. I'm not sure if anything else can be done without capturing data from a working early unit in action. If someone has any ideas on how to get one running, I'd be willing to donate a Supercharger unit (if they pay for shipping) as long as they have the necessary skills and are willing to share the results.

Sounds like someone needs to find a secluded supercharger location and break out the toolbox

annyung wrote: ↑Wed Sep 23, 2020 3:33 am Using the v5 board I am getting 125VDC from each module.

Hi.

I'm new to this exact application, but experimented with CAN hardware debugging... Have you played with the V5 code a little or tried differents setting in the serial interface? (in order to see the effect of the voltage target sent in CAN). Maybe this is just a scaling problem in the messages themselves that can easily be adjusted for the few chargers harware versions that came from superchargers.

Example: if the Vtarget was set to 386V and you get 125VDC, then manually forcing Vtarget to other values and comparing the new V_outputs will help us guess if it's a scaling problem, or simply another offset reference, or both. If there seems to be a ceiling at 125V, try lowering the V_target to see what can make this output fluctuate... then we'll be able to try new ways to make it work.

Are you able/equipped to try these tests?

Jack Bauer wrote: ↑Wed Sep 23, 2020 7:16 am Crazy thought but how about working out the differences in the CAN messaging and getting these chargers working then submitting the software on github? Lots of engineers on fiverr.com if you lack the skills.

I bit the bullet and bought a 05 unit!
I only have no clue if i can give it any use in EU at all?
Is it compatible with 230 single or three fase?

So i will try if i can fix this scaling related issue and make the cheaper super chargers work.
The only thing i need is a Gen 2 board....

They are 3 separate one phase chargers
I would believe they run on 240V split phase in US super chargers so should handle 230V single phase

Looking forward to your findings

I can donate an old rev board for free. Just needs a cap and voltage reg mod. Shoot me a pm with your address and I'll throw it in the post during the week if that works.

Jack Bauer wrote: ↑Sat Apr 10, 2021 1:32 pm I can donate an old rev board for free. Just needs a cap and voltage reg mod. Shoot me a pm with your address and I'll throw it in the post during the week if that works.

Ok that's cool!
Will PM you.

Ok shouldn't be too long before we can start!
Sadly the seller is on the otherside of the USA so it takes a bit more time.

The mouser connectors are inbound too.
(The 12pole molex is on backorder... though)

It's in!
Waiting for a small package from Ireland

p.s. It's sitting on something for another thread....

OK working on it.

First thing i found is that the Tesla board has 60Ohm on the CAN-Bus we got 120Ohm.
Don't know if at high burst it will screw-up the canbus but its an easy fix. It means that the charge modules it self aren't terminated.

For the rest the board is flashed (needed to setup this STLink dongle stuff), transplanted the OEM connectors (dammn tricky stuff), charger is connected (one module to single phase 240VAC).

Tomorrow i proceed with powering it up using 12volts and giveing it some custom firmware.

Plan: I first am gonna try to get one module up and running, then with 3 at a time.


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)

Ok so the board you have is a V5B2. Schematic here :
https://github.com/damienmaguire/Tesla- ... ematic.pdf

Changes required :
C3 change from 0.1uf to 10uf
3v3 reg LD1 may require an upgrade to the part supplied. Requires some bodging.

Your power module can should read 60 ohms as there is a termination resistor on the logic board and also on the power modules (i forget which one)
R1 on schematic above.

Jack Bauer wrote: ↑Sat Apr 24, 2021 9:43 am Ok so the board you have is a V5B2. Schematic here :
https://github.com/damienmaguire/Tesla- ... ematic.pdf

Changes required :
C3 change from 0.1uf to 10uf
3v3 reg LD1 may require an upgrade to the part supplied. Requires some bodging.

Your power module can should read 60 ohms as there is a termination resistor on the logic board and also on the power modules (i forget which one)
R1 on schematic above.

If i measure the CANL and the CANH i get 60Ohm on the tesla board (removed from the unit), didn't add that last addition which is important.
I get 120Ohm on mine plugged or not plugged in. So i think that SuperChargers or my HW revision don't have the terminator in.
Makes sense because in the supercharger-setup you would over terminate perhaps.

I started of with the V5 software and found a bug: rownr: 1398 i think its a division by zero. active modules van be 0 and you cant divide by that.
I will fix that in my Debug version. I have no clue yet what you will see in a normal environment, perhaps you get watchdog resets?

Didn't do the changes yet which you describe. Thank u for clearing it up.

Can someone of you guys with a working charger please post the partsnumbers of the components listed?
I truly need and want to know this.

Question: i don't have an EVSE do i need one to charge? Or could i potentially modificate the code to just run the charge modules..so the question basicly is: the pilot signal on the molex side, is that going only to our board or also to the chargers?

I'm getting a fast course into this stuff

You should probably ready the wiki and previous manual iterations before actually applying power. This stuff is all documented with and without evse.

jon volk wrote: ↑Sat Apr 24, 2021 4:27 pm You should probably ready the wiki and previous manual iterations before actually applying power. This stuff is all documented with and without evse.

Well can you be a bit more precise?
The GEN2 wiki i read and editted it.
In the thread which is very very long..i downloaded to captures etc.

about non EVSE my question is still unanswered.

Input type manual
Reading though the old documents on Damiens GitHub should add further detail. Variable names are generally consistent throughout.

Jack Bauer wrote: ↑Sat Apr 24, 2021 9:43 am Ok so the board you have is a V5B2. Schematic here :
https://github.com/damienmaguire/Tesla- ... ematic.pdf

Changes required :
C3 change from 0.1uf to 10uf
3v3 reg LD1 may require an upgrade to the part supplied. Requires some bodging.

Your power module can should read 60 ohms as there is a termination resistor on the logic board and also on the power modules (i forget which one)
R1 on schematic above.

Can you elaborate on where the CONT1 and CONT2 go? They are on the 30PIN header but on the MCU there aren't present...
Are those inputs? Feedback from the coils? Are those inputs going internally to the charge modules themselves?

I'm trying to improve my Test bench by adding relais for 400VDC and 230VAC to the modules.
The complete setup is very timeing sensitive it seems....

I am making progress though...

Not used. Leftover pins from a previous hw version. The only time critical part is the application of ac power.

Ok, will check your video.

So the only thing the charge modules see are the connections of DC, AC and the IO of the JST connector correct?

The molex is going only to our board?

I have the VAC On now switched by OUT2.