Tesla Model S UMC disassembled. It's a bit difficult to disassemble because they used two plastic exterior shells and filled it with a black plastic material. There's really no air in there (or a place for water).
The aluminum top piece (with TESLA on it) is just glued on, and pops off easily, but probably not without bending. The six holes you see in the black exterior shell directly under the aluminum bit are what I drilled "looking for screws". Of course, they don't use any!
Those holes were where they injected the black plastic that you see all around all the wires. Even the circuit card for the J1772 proximity switch and the remote control for the charge port door is "glued in" with this black plastic.
Wire colors:
1) Red - Neutral or L2
2) Black - Hot L1
3) Green with Yellow strip - apparently how the Chinese make a green ground/earth wire
4) Purple - pilot signal
5) Blue - 3.3 volts to power remote control transmitter from UMC "box"
6) Green - probably ground for the remote control transmitter (this does not leave the UMC plug handle)
7) Orange - probably an antenna for the remote control transmitter? (this does not leave the UMC plug handle)
S1 is the switch for the J1772 proximity circuit. R1 is the 150 ohm resistor that signals the proximity pin is connected to the car. When the S1 switch is pressed (closed), the 330 ohm resistor R2 is added in series to R1, creating 480 ohms to ground (150 + 330) which signals to disconnect. Yep, that simple.
S2 is the switch for the transmitter that opens the Model S charge port. It is powered from the UMC with 3.3 volts from the blue wire.
Left to right, proximity pin, ground pin, pilot pin
Aren't these beautiful? They feel SOLID! They don't have any anti-rotating devices. Industry standard 4 indent crimp. No seals around these pins; they just sit in the plastic holder.
The other pins except the two power pins do have seals around them. Those parallel conductors in each power pin are about 12 gauge (sorry, I don't know the metric equivalent)
See the lining in the socket of the lower power pin? I don't have a very good picture of the center coaxial pin in the socket. It's made out of a different material than the socket, which is likely a copper alloy.
