Solid Red Light of Death Tesla HPWC wall charger

Solid Red Light of Death Tesla HPWC wall charger

This is just what I have done and in no way coverers every case out there. Disclaimer working on electric can kill you so if you don’t know what you are doing don’t do it.

Yes, you can rebuild your Tesla HPWC with simple off the shelf parts and in fact make it much better by adding WIFI and much more flexible control even a display.

Wiring the OpenEV Advanced Series - Component Set with WIFI into the Tesla Wall Charger.

Wires you will use from your old cable.
• Large Red
• Large Black
• Large Green for ground
• Small Purple – Pilot
• Small Blue – 3.3v for the charge door open button (note this taps into the 3.3v output of the WIFI board and still works as it always did to open the charge port)

Wires that you will cap off and not use
• Small White
• Small Black
• Small Orange

I won’t go into wiring details since the kit and website have very detailed instruction step by step.

I’m also not going to list the standard tools you will need like a screwdriver and wire cutters but here are some things you may need to complete the job that are not in everyone’s toolbox.

• Cable Lugs. Since the Tesla wall charger is up to 48amps depending on the service cable you have run to your wall charger you many need to install cable lugs on the wires to terminate them on the relay. Remember this is high current so you want a very solid connection this is why I recommend this. I ran #6 gauge to my charger I know some run #4 so you will need to get the correct size lugs and you only need 2 of them but get a pack. I used 6 AWG-#10 Ring this matched my feed wire and is the correct size for the relay terminals.
• Cable Lug crimper. This is not the baby one that you may have on some pliers that is used for electronics terminals. This type crushes the terminal from all sides creating a hexagon crimp.
• If you don’t have shrink tubing best to get some makes for a nice job but is not mandatory.

Understand these chargers are not very complicated it’s just a relay, control board and some wiring.

First thing you need to do is Turn The Power OFF. Then open up your old charger and take all the guts out of it. I went ahead and custom made out of junk plastic a base to mount the new hardware. This is optional but sure does make the job easy and look better.

Here is the link to the kit I purchased https://store.openevse.com/collections/all-products/products/advanced-kit

You actually do not need the kit with the housing if you are reusing the old Tesla case but this kit for $40 more includes some other parts I plan to use on a different project. Also, if during your build you don’t want to use the old Tesla case you have a case.

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