Gen 3 Wall Connector Manual 48A Single Phase
Important Safety Information........................... 2 Product Overview.................................................. 5 Product Specifications......................................................... 5 Circuit Breaker Rating / Maximum Output.................. 6 Using Wall Connector...........................................................8 Features................................................................................... 10 Connectivity.......................................................
IMPORTANT SAFETY INFORMATION Read all instructions before using this product. Save these instructions. Wall Connector features built-in Type B RCD . This manual contains important instructions for the Tesla Gen 3 Wall Connector that shall be followed during installation, operation, and maintenance. Please review all warnings and cautions before installing and using the Wall Connector. WARNING: When using electric products, basic precautions should always be followed, including the following.
IMPORTANT SAFETY INFORMATION WARNING: Do not touch the Wall Connector’s end terminals with fingers or sharp metallic objects, such as wire, tools, or needles. WARNING: Do not insert fingers or foreign objects into any part of the Wall Connector. WARNING: Do not forcefully fold or apply pressure to any part of the Wall Connector or damage it with sharp objects.
IMPORTANT SAFETY INFORMATION CAUTIONS CAUTION: Do not use private power generators as a power source for charging. CAUTION: Incorrect installation and testing of the Wall Connector could potentially damage the vehicle's battery, components, and/or the Wall Connector itself. Any resulting damage is excluded from the New Vehicle Limited Warranty and the Charging Equipment Limited Warranty.
PRODUCT OVERVIEW This manual applies to Wall Connectors identified by part number 1457768-**-*. Product Specifications Voltage and Wiring Nominal 200-240 V AC single-phase Current Output Range 12 – 48 amps Terminal Blocks 12-4 AWG (3.5 - 25 mm2), copper only Supported Conduit Sizing ¾ in (21 mm) default, 1 in (27 mm) optional Grounding Scheme TN/TT Frequency 50/60 Hz Cable Length 7.3 m (24 ft) Wall Connector Dimensions Height: 13.6 in (345 mm) Width: 6.1 in (155 mm) Depth: 4.
PRODUCT OVERVIEW Circuit Breaker Rating / Maximum Output Power Output For maximum power output, install a standard double pole 60 amp circuit breaker. Wall Connector includes integrated GFCI protection - do not install a GFCI circuit breaker. Wall Connector incorporates automatic load management, which allows the max output to be customized to an existing power supply. If the electrical supply is unable to support the 60 amp configuration, select a lower amperage configuration.
PRODUCT OVERVIEW Grounding Connections Wall Connector must have a ground path back to the main equipment earthing point on site. Without a proper ground connection, the Wall Connector will fault during a ground assurance test. Equipmentgrounding conductor must be run with the circuit conductors and connected to the equipment-grounding terminal in the wirebox. Install a ground (PE) wire sized according to local electrical code.
PRODUCT OVERVIEW Using Wall Connector 1. Open the vehicle charge port by pressing the button on the charge handle, pressing on the charge port door, using the mobile app, using the vehicle touchscreen, or by pressing and holding the trunk button on the keyfob. 2. Insert the charge handle into the vehicle charge port. 3. Check the vehicle controls to verify charging. 4. To remove the charge handle from the vehicle, press and hold the button on the handle to unlock the charge port.
PRODUCT OVERVIEW Gen 3 Wall Connector Manual 9
PRODUCT OVERVIEW Features Connectivity Wall Connector is equipped with Wi-Fi to communicate with local site routers, vehicles, mobile devices, other Wall Connectors, and other Tesla products. Hosted Access Point Wall Connector hosts a WPA2 password-secured, 2.4 GHz, 802.11 Wi-Fi access point network to facilitate commissioning and connecting to other devices.
PRODUCT OVERVIEW NOTE: Property management features will be enabled via future firmware updates.
PRODUCT OVERVIEW Ground Fault Circuit Interruption Integrated ground fault circuit interruption (GFCI) protection automatically detects a current mismatch between power delivery conductors that would indicate that current is flowing through the ground (PE) conductor. If a ground fault occurs after 10 seconds of charging, Wall Connector will wait 15 minutes before automatically re-attempting to charge. Up to four attempts to charge will be made before user interaction is required.
PRODUCT OVERVIEW Thermal Monitoring Wall Connector actively monitors temperatures in multiple locations while charging to ensure stability of the charge session. Temperature sensors are located at the relays, microcontroller, charge handle, and rear of the main unit to monitor the temperature of the terminals in the wirebox. In warmer conditions, Wall Connector may reduce current and charge speed to protect itself.
PRODUCT OVERVIEW Wall Connector External Components "Wall Connector" refers to the product as a whole. 1. Faceplate 2. Light bar (vertical) 3. Main unit 4. Charge handle button 5.
PRODUCT OVERVIEW Wall Connector Internal Components 1. RS-485 port 2. Contact blades 3. Temperature sensor 4. Conductor terminals 5. Zip tie anchor 6. Sliding contacts 7.
INSTALLATION In the Box Hex Bit (4 mm) Main Unit Zip tie (x1) Wirebox Wirebox Mounting Template Wall Connector-toWirebox Fastener (x4) Wirebox-to-Wall Fastener (x2) Quickstart Guide (contains sticker with SSID network name and unique password) SAVE THIS DOCUMENT NOTE: The hex bit, zip tie, and fasteners are located in a plastic bag inside the wirebox, which comes attached to the main unit of the Wall Connector. NOTE: Wall plugs are not included.
INSTALLATION Tools Required Tools NOTE: Drill bit sizes assume wood mounting surfaces. If installing on concrete or other masonry, consult with an electrician for optimal pilot hole sizes. Stud Finder Torque Driver (50 lbf . in, 5.6 Nm) Multimeter Tape Measure Bit Driver Wire Stripper Drill Bit, 1/4 in (6.
INSTALLATION Installation Considerations Wall Connector may be installed on any flat, vertical surface capable of supporting its weight (e.g. wall, pedestal, etc.). Wall Connector weighs . Choosing Location Install Wall Connector in a location that allows the charge cable to reach the vehicle charge port without putting strain on the cable. Recommended installation area for Wall Connectors with 24 ft (7.
INSTALLATION Choosing Height • Maximum height (indoor and outdoor): 60 in (1.52 m) • Recommended height: ~45 in (~1.15 m) • Minimum outdoor height: 24 in (0.6 m) • Minimum indoor height: 18 in (0.45 m) Maximizing Wi-Fi Signal Reception Wall Connectors should be connected to a local Wi-Fi network for optimal functionality.
INSTALLATION Wire Entry Options Wall Connector's wirebox has multiple wire entry options. Choose one entry path and follow installation instructions based on chosen entry path. 1. Top entry location 2. Rear entry locations (left or right) 3. Bottom entry location For additional installation considerations on sites that will have multiple Wall Connectors, see Considerations for Power Sharing on page 33.
INSTALLATION Step 1: Prepare Wirebox for Conduit Fittings and Bushings The default conduit size is 3/4 in (21 mm). 1 in (27 mm) conduit is acceptable if needed. Based on fittings and conduit size, prepare the wirebox. • For top or bottom entry: Manually remove the conduit plug. • For rear entry: Drill with 1-1/8 in (29 mm) step bit to prepare wirebox for fittings. Table 1. For 3/4 in (21 mm) Conduit Top Entry Bottom Entry Rear Left Entry Rear Right Entry 1-1/8 in (29 mm) 1-1/8 in (29 mm) Table 2.
INSTALLATION Step 2: Prepare Mounting Surface 1. If applicable, use a stud finder to locate a wooden support stud. Plywood, or other flat wall surfaces capable of supporting the weight of the Wall Connector, may also be used. 2. Based on the chosen wire entry path, position the included cardboard mounting template onto the installation surface and use a 5/32 in (4 mm) bit to drill two pilot holes (one from the top row and one from the bottom row).
INSTALLATION Step 3: Prepare Wirebox and Mount to Wall 1. Use a 1/4 in (6.5 mm) bit to drill two pilot holes into the wirebox that match the locations chosen on the cardboard mounting template. Drill bit, 1/4 in (6.5 mm) Top Entry Bottom Entry Bottom Left Entry Bottom Right Entry 2. Attach the wirebox to the mounting location using the included 4 mm hex bit and the two included wood fastener screws. NOTE: Type 3R rating is only possible when washers have sealing gaskets.
INSTALLATION Step 4: Route Wiring Through Wirebox 1. Route wiring into selected entry point and through the service loop channel on the right side of the wirebox. Top Entry Bottom Entry Rear Left Entry Rear Right Entry 2. Use appropriate cable glands, bushings, or fittings to secure the wiring in place and protect from water and debris intrusion. CAUTION: Ensure that bushings are in place to avoid damage to conductors and ground wire when pulled into wirebox. CAUTION: Use copper conductors only.
INSTALLATION Step 5: Strip and Land Wiring 1. Strip insulation from wires ~1/2 in (~13 mm), route through service channel, and land each wire in its correct terminal block. NOTE: Terminals are bi-directional. 2. Secure the wiring in the service channel using the included zip tie. 3. Use a torque driver and the included 4 mm hex bit to torque the terminal screws to 50 lbf . in (5.6 Nm). NOTE: When installing Wall Connector in a split phase electrical system, use Line-to-Line instead of Line-to-Neutral.
INSTALLATION Step 6: Attach Wall Connector to Wirebox 1. Attach the main unit to the wirebox by pushing it inward. 2. Secure the main unit to the wirebox with the four included fasteners and the included 4 mm hex bit using a bit driver, applying pressure to the faceplate during the process to compress the internal seal. Firmly hand-tighten the four fasteners until they are secure. NOTE: Do not use a power drill for this step.
INSTALLATION Step 7: Energize Wall Connector 1. Energize the Wall Connector by turning on the upstream circuit breaker. The Wall Connector's LEDs will turn on. See Wall Connector LEDs on page 36. 2. Proceed with commissioning.
COMMISSIONING PROCEDURE The commissioning process for Wall Connector enables easy configuration of circuit breaker size, Wi-Fi connectivity, and power sharing options. 1. Turn on Wall Connector's corresponding branch breaker to energize the unit. During startup, Wall Connector will display green LEDs for 10 seconds to indicate the maximum circuit breaker it is configured for. 2. Use a Wi-Fi-enabled device such as a smart phone to connect to the SSID Wi-Fi signal broadcasted by the Wall Connector.
COMMISSIONING PROCEDURE NOTE: To have the Wall Connector broadcast the SSID again, hold the button on the charge handle for 5 seconds or turn the circuit breaker off, then on again. Setting Up Access Control The Charging Access Control feature provides full control over which vehicles are allowed to charge with your Wall Connector and excludes vehicles without access based on user specifications. 1. Sign into the commissioning wizard..
COMMISSIONING PROCEDURE Gen 3 Wall Connector Manual 30
POWER SHARING Power Sharing Overview The firmware-based power sharing feature enables up to 6 Wall Connectors installed at the same site to intelligently share the site's total available power via unit-to-unit Wi-Fi. This minimizes the need for many residential and commercial applications to have specific electrical upgrades for concurrent multi-vehicle charging.
POWER SHARING Breaker and Branch Circuit Setup Power sharing circuits may be installed in an electrical panel that supports other loads. If space is limited or the main power supply is far from the Wall Connectors, installing a dedicated load center may be prudent. See below for examples of Wall Connector power sharing diagrams (one with sub-panel and one without). Each individual Wall Connector in below examples is capable of providing 48 amps when it is the only one in use.
POWER SHARING Considerations for Power Sharing Wall Connector power sharing is achieved wirelessly. For optimal performance, Wall Connectors within a power sharing network should be installed within view of each other whenever possible. NOTE: Line of sight is recommended but not required. Wireless communication is capable of reaching around concrete corners but network range may degrade as a result.
POWER SHARING Power Sharing Commissioning Procedure 1. Identify and configure the wall connector. One Wall Connector will be the designated leader and provide the configuration and controls for all followers. Install and configure the leader first. Follow the process in the Commissioning Procedure on page 28 to connect and configure the leader. 2. Add up to five additional followers from the lead Wall Connector.
POWER SHARING NOTE: In the event that your leader and followers have different circuit breakers, you have to individually connect to each of the followers on different breakers via the Wi-Fi broadcast, and then set the correct breaker limit.
WALL CONNECTOR LEDS Light Codes Startup Once energized at the circuit breaker, every LED (seven total) on the faceplate will illuminate for up to five seconds. After Startup After Wall Connector is energized at the circuit breaker, certain green LEDs (depending on the circuit breaker size) will illuminate for 10 seconds. See table below for exact light codes.
WALL CONNECTOR LEDS Standby, waiting to plug in Gen 3 Wall Connector Manual Charging in progress SSID broadcasting, ready to commission Waiting to charge, communicating with vehicle 37
WALL CONNECTOR LEDS Fault Codes All red blink codes pause for one second, and then repeat. Light Bar What It Means Details No Lights Power supply issue, charging disabled Verify that the power supply is turned on. If the issue persists, have an electrician remove the Wall Connector from the wirebox and confirm that voltage is present at the terminal block using a multimeter. Record the voltage readings for the following: L1 to L2/N, L1 to Ground, L2/N to Ground.
WALL CONNECTOR LEDS Additional Assistance for Red LED Faults A Wall Connector's alerts are visible in the browser commissioning wizard (for instructions on how to connect to the commissioning wizard, see Commissioning Procedure on page 28).
WARRANTY INFORMATION Subject to the exclusions and limitations described below, the Charging Equipment Limited Warranty covers the refund, repair or replacement necessary to remedy any manufacturing defects in a Tesla manufactured and supplied Wall Connector that occur under normal personal use for a period of 48 months, or a period of 12 months for normal commercial use*, and a Tesla manufactured and supplied Mobile Connector or charging adapter that occur under normal use for a period of 12 months, starti
WARRANTY INFORMATION Limits of Liability This Charging Equipment Limited Warranty is the only express warranty made in connection with your Tesla connector or adapter.
WARRANTY INFORMATION Dispute Resolution To the fullest extent allowed by local law, Tesla requires that you first provide written notification of any manufacturing defect within a reasonable time, and within the applicable coverage period specified in this Charging Equipment Limited Warranty, and allow Tesla an opportunity to make any needed repairs before submitting a dispute to our dispute settlement program (described below).
WARRANTY INFORMATION enforced as to a particular claim for relief or remedy (such as injunctive or declaratory relief), then that claim or remedy (and only that claim or remedy) shall be severed and must be brought in court and any other claims must be arbitrated. If you prefer, you may instead take an individual dispute to small claims court. You may opt out of arbitration within 30 days after signing this Charging Equipment Limited Warranty by sending a letter to: Tesla, Inc.; P.O.
Revision 1.
