[Martii]

First V2 boards off the production line

Sweet, great looking.

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[CKidder]

Maybe I missed it but did anyone ever post a reference for the connectors on a gen 2 charger? I'm interested in the best way to connect to the AC and DC sockets on the thing. I could probably easily figure out the AMPSeal connector on the other side. But, if someone has the part# it'd save me from looking it up. Thanks

 

[Martii]

First V2 boards off the production line

Damien,

What is IC5 for? I've checked schematics and was thinking that this is for activation of 12V per charger module. But after closer investigation I see that 12V goes directly to all modules?

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[CKidder]

Damien,

What is IC5 for? I've checked schematics and was thinking that this is for activation of 12V per charger module. But after closer investigation I see that 12V goes directly to all modules?

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IC5 is a transistor array that's used to create strong outputs from the board. It's used to do things like drive relays directly from the control board.

 

[Martii]

IC5 is a transistor array that's used to create strong outputs from the board. It's used to do things like drive relays directly from the control board.

So this will be used to drive relays on the junction box?

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[Kevin Sharpe]

Maybe I missed it but did anyone ever post a reference for the connectors on a gen 2 charger? I'm interested in the best way to connect to the AC and DC sockets on the thing.

I believe the crimp housing is Molex 44441-1006 (here)

 

[Kevin Sharpe]

So this will be used to drive relays on the junction box?

The two inverter contactors (see here)

 

[jackbauer]

Thanks for that link Kevin. Always thought those connectors were a Tesla special but should have know they would use off the shelf. I must do a wiring diagram for the charger connectors. I only used 3 wires when testing : +12v , GND and a relay drive to turn on the mains.

 

[Martii]

Thanks for that link Kevin. Always thought those connectors were a Tesla special but should have know they would use off the shelf. I must do a wiring diagram for the charger connectors. I only used 3 wires when testing : +12v , GND and a relay drive to turn on the mains.

Do you really need to use relay to turn on mains?

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[CKidder]

Do you really need to use relay to turn on mains?

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It seems that unfortunately you do. The charger wants to see zero volts on the mains side until a certain point and then you can turn it on. There's a whole song and dance number to go through to make it work. It was discussed back in this thread somewhere.

 

[CKidder]

I believe the crimp housing is Molex 44441-1006 (here)

Indeed it is! I ordered parts from DigiKey and it all fits. Here is what I ordered:

044441-2006 (black instead of natural, they don't stock the 1006)
1718250100 (10-12ga female blade crimp connector)
0433750001 (14-16ga female blade crimp connector)

It looks like the wiring in the charger is around 14ga so I can probably use that for the external wiring too.

Now, my next question would be, what's the pinout? I'm guessing that red and black is probably AC hot/neutral for three phases? Are the white, brown, purple, and yellow wires the output DC to the battery? White being ground and the colored wires being positive? I don't seem to have any schematic for the car that lists this connections.

 

[Martii]

Indeed it is! I ordered parts from DigiKey and it all fits. Here is what I ordered:

044441-2006 (black instead of natural, they don't stock the 1006)
1718250100 (10-12ga female blade crimp connector)
0433750001 (14-16ga female blade crimp connector)

It looks like the wiring in the charger is around 14ga so I can probably use that for the external wiring too.

Now, my next question would be, what's the pinout? I'm guessing that red and black is probably AC hot/neutral for three phases? Are the white, brown, purple, and yellow wires the output DC to the battery? White being ground and the colored wires being positive? I don't seem to have any schematic for the car that lists this connections.

Red and black is DC part.

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[Tomdb]

Unfortunately due to everyone using different colours I can understand the confusion.

Best part is the way Tesla connect to both connects is with completely orange jumpers. However red and black are positive and negative.

Did someone end up making an overview of the pinouts on the signal connectors with the new logic board installed?

 

[Martii]

Unfortunately due to everyone using different colours I can understand the confusion.

Best part is the way Tesla connect to both connects is with completely orange jumpers. However red and black are positive and negative.

Did someone end up making an overview of the pinouts on the signal connectors with the new logic board installed?

It's done on Damiens github

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[Tomdb]

Not that I can see, I can see what signals go onto the connector on the board, but no translation to the connectors on the case.

Otherwise, I will measure the connections and create a nice little diagram for all.

 

[jackbauer]

Reds are battery positive. Blacks are battery negative. White are AC Neutral and Colours are AC phase.

 

[CKidder]

Reds are battery positive. Blacks are battery negative. White are AC Neutral and Colours are AC phase.

Thanks, that does make perfect sense now that I think about it. So the reds and blacks can be paralleled together to get the full 10kw of charging then the input wires could be paralleled or run as separate phases. I have 208V, 240v, and 480v three phase available so I can go to full three phase and run each module off of a different phase.

So, another question. The charger is rated to 400v supposedly. Am I to assume that I should not power it with 480V three phase?

 

[jackbauer]

When I did some investigation on the EU HVJB it does indeed just parallel the DC wiring. The AC wiring is either paralleled for high current single phase or split to use phase to neutral on a 3 phase system. I'm not sure what the US version does but I'd say it just parallels the AC for high current single phase. I have only ran the charger from 230v single phase but did wind it up to 10kw for a few minutes.

One thing to be very careful about is the current command. You are NOT commanding battery current but rather AC line current. What battery voltage are you planning to use? Don't make my mistake and try and run high current with a 120v pack

 

[Tomdb]

Damien, OUT4 connects to which pin? Conn 2 pin 4.

That is the only signal I could not map.

 

[Kevin Sharpe]

I can confirm the main PCB in the US and EU HVJB are identical. On the US HVJB two contractors are removed (K1 and K3) and a copper bus bar is used to short AC inputs L1/L2/L3 together.

I've traced out all the connections on the HVJB and have started producing a schematic which I'll share once complete. In the meantime here's the main HV AC/DC circuit excluding the current sense and fuse that supplies power to the Front HVJB.