I bought a Tesla Model S Gen 2 Charger - Now What?

PARTS NEEDED SECTION

1. Charger - Tesla Gen2 Charger Compatibility and Ebay WARNING


not all Gen 2 onboard chargers were created equally in other words they all may work fine in an actual Tesla but they don't all lend themselves to a DIY EV Conversion open source charger setup







2. Tesla Gen 2 Charger Logic Board from Damien Maguire's EVBMW.com web shop Price: 270.00€ this is a direct replacement and lives inside the stock charger housing, you unscrew the old board and screw this one in it's place, well after a bit of programitization of course



V5 Logic board for the Tesla GEN2 onboard battery charger.
Soldering required
Connectors NOT supplied. Please see attached connector BOM for part details.
Supplied fully programmed with WiFi module.
Fits all GEN2 chargers both master and slave.
Price includes worldwide tracked postage.
Fully open source project.
Support via the openinverter.org Forum
Software and resources available on Github

Charger running at full power
Delivery : 1-3 weeks from order depending on stock.
No tax or other surcharges.

3. AC / DC Connectors - I'm guessing these are going to carry the AC electrons from the wall of our garage to the DC electrons in our battery pack, I have not seen any pics of these DIY wiring diagrams or DIY connections yet, will post them when I find some, if you did this already please share some pics with us


4. Logic Connectors - so aside from 12 volts power and a ground these will run two additional skinny wires to the charge port one for the Proximity Signal (?) and the other for the Control Pilot signal (?) (both found on the larger 12 pin plug on the right) see further below for wiring detail


PART NUMBER:330122001

MX150 Female Terminal for Mat-Sealed Connectors, Tin Plating, 14 and 16 AWG, Right Reel Payoff



5. Plug Port and Harness

So can we just use something "Universal" like this: EV Inlet Socket - 32A 250V AC Type 1 Electric Car Recharge Socket

alright here is what plugs in to the other end on the stock vehicle it may be known as the Master High Voltage Onboard Charger Harness 1037646 it appears to go into a HVJB high voltage junction box on the other end, out of which some orange wires run to the inverter, not sure where the other orange wires go to, perhaps the battery pack, maybe someone can comment











The High Voltage Junction Box shown below to the right of the charger with all the orange guts inside of it is for demonstration purposes only, it is not needed to get the charger to function fully. In this pic Damien was just using it so that he could easily connect thicker heavier gauge wire to the charger via the junction box.

ACRONYMS and more ACRONYMS

EVSE stands for Smart Charging Solutions for Electric vehicles, say what? Electric Vehicle Supply Equipment (EVSE) provides for the safe transfer of energy between the electric utility power and the EV. EVSE includes EV charge cords, charge stands (residential or public), attachment plugs, vehicle connectors, and protection. it's a darn EV charging station, that's all

Here is a good primer video on Charging Station status signals EV Charging Station EVSE - What is pilot and proximity? by OpenEVSE


HVJB, HVJB, HVJB oh the acronyms, I recon this one is High Voltage Junction Box and there may be a front one and a back of the vehicle one

OBCM - On Board Charging Module, aka Charger (basically different manufacturers come up with their own namings for things)

kWh - pronounced "gallons" as in I have a 24 gallon fuel tank (think Nissan Leaf's 24 kWh battery pack) or in the case of a Chevy Volt and it's 16 kWh battery pack size, so our analogy would say 16 gallon fuel tank, kilo Watt hours so 1,000 times Wh or Watt hours (just add three zeros "000") Tesla had a 60 kWh battery pack once, so that would have been the 60 gallon fuel tank analogy. Keep in mind that just because your fuel tank can hold 20 gallons that does not mean that's how much actual fuel you have in it at any given time, kapish.

PWM, we can't have an EV discussion without mentioning Pulse-width modulation

SAE, Society of Automotive Engineers

LOW VOLTAGE CONTROL SIDE WIRING

alright let's label the low voltage Logical connectors and see if we can plan how to wire them up

View attachment 124083


so this is from Damien Maguire's instructions



Following the diagram above,

1. Connect your 12V+ to B1 (labeled 12V+) and A3 (labeled IN1)
2. Connect your 12V- to B7 (labeled GND) and to the charger's casing (chasis ground)
3. Connect the Proximity signal from your EVSE to B11
4. Connect the Control Pilot signal from your EVSE to B5.

View attachment 124109

so I was just looking at this SAE J1772 plug pin out trying to get the color coding of the Proximity Signal and Control Pilot Signal wires for consistency sake. The Proximity Pilot signal indicates how much current the cable can handle.






And here's a look at what that hair dryer plug will actually plug into on our cars, this below is what most often is shoved inside the ol' fuel tank filler neck.

AC Input Connector & DC Output Connector

so let's take a look at the business end of this magical box, inside there there are three power modules, so on the DC output side we get three pairs of -/+ wires, a pair goes to each one of the three modules

[a huge thanks to Yoda Artur for helping me finally get this]

pic from Damien's PDF instructions



so this below shows Live and Neutral AC Input pins as well as the Positive and Negative DC Output pins







In it's simplest configuration we could just wire up one module (leave the other two disconnected from both AC and DC) and only connect one Negative/Positive DC wire pair to our battery pack

Damien Maguire's YouTube Video Series (how it all went down years ago and what it took to reverse engineer this gen 2 charger)





Aug 31, 2017 The Tesla Project : 10 Kw Gen 2 Charger

Oct 2, 2017 The Tesla Project : Charger Progress

Oct 18, 2017 The Tesla Project : 10kW Charger Charging

Oct 21, 2017 The Tesla Project : Tesla Charger Arduino Control

Oct 23, 2017 The Tesla Project : More Charger Hacking

Jan 8, 2018 The Tesla Project : Charger 10kw Run