I have an early HPWC... I received it in about April of 2013, just before I got my car. It had the original "small" fuses that had issues when operating at 80A. Tesla offered (physically) larger replacement fuses at the time, but I never did obtain a set, and as I was operating on a 50A circuit didn't really pursue it.
On Monday morning, I came out to a dead HPWC. My breaker in the panel was fine, and a reset didn't help. Opened up the HPWC, and as I had suspected, one of the 2 fuses was blown.
Given the car is only drawing half of what they are rated for, and the 50A fuses in the car charger didn't go, I don't believe it was an overcurrent failure. All indications are that the torque on the fasteners was still good, as the marks were still correct. No significant discoloration of the fuse contact tabs or mounting terminals. My feed wiring is tight in the lugs and no discoloration there. Given the low current draw, I don't think high heat was a problem.
I think the fuse just died with cycle life. I had a fuse in one of my car's chargers also die a number of months back (although I've not put that charger back in to service to check, several folks have similarly had them go, only to replace them and have the charger continue fine).
It so happens that Telsa shipped me an entirely new HPWC about a year in to ownership when I had some charging issues (which subsequently to have been related to a dirty pilot signal pin). So I'm going to swap HPWC's completely, rather than just replace the fuse and put this one back in to service. (Hoping to relocate it anyway, and the charge connector on the old HPWC got run over, damaging the port button)
So... just sharing a bit in case anybody else had similar issues.
On Monday morning, I came out to a dead HPWC. My breaker in the panel was fine, and a reset didn't help. Opened up the HPWC, and as I had suspected, one of the 2 fuses was blown.
Given the car is only drawing half of what they are rated for, and the 50A fuses in the car charger didn't go, I don't believe it was an overcurrent failure. All indications are that the torque on the fasteners was still good, as the marks were still correct. No significant discoloration of the fuse contact tabs or mounting terminals. My feed wiring is tight in the lugs and no discoloration there. Given the low current draw, I don't think high heat was a problem.
I think the fuse just died with cycle life. I had a fuse in one of my car's chargers also die a number of months back (although I've not put that charger back in to service to check, several folks have similarly had them go, only to replace them and have the charger continue fine).
It so happens that Telsa shipped me an entirely new HPWC about a year in to ownership when I had some charging issues (which subsequently to have been related to a dirty pilot signal pin). So I'm going to swap HPWC's completely, rather than just replace the fuse and put this one back in to service. (Hoping to relocate it anyway, and the charge connector on the old HPWC got run over, damaging the port button)
So... just sharing a bit in case anybody else had similar issues.