I started experiencing issues with my gen3 Tesla Wall Connector. It would start charging and then immediately stop, the Tesla logo on the charging port would flash red. I decided to take the wall connector apart to investigate further.
After doing a visual inspection on the board, I noticed the power pins on the relays that deliver the charging current to the vehicle had signs of overheating. It sort of looked like burn marks. I actually went ahead and opened the casing on one of the relays, trying to get a better look inside. I find it kind of surprising that the legs inside the relay are so thin, you would think they would design them to be thicker, preventing overheating.
Anyways, I decided to attempt a repair. What I did was, remove both power relays and replace them with new ones that I found online. I realize they are the same and I wonder if they won't inevitably fail the same way in the future. Still, I thought it was worth a shot. Alternatively, I thought about adapting a more chunky relay on the board, but the transparent cover of the wall connector leaves no room for a bigger relay.
After soldering in the new relays, it has been working well for a couple of charging sessions at full 48A. I'll continue to test it, to see how long my DIY repair will be good for. If you're interested, I captured a video of how I did the repair and posted it on my YouTube channel here:
After doing a visual inspection on the board, I noticed the power pins on the relays that deliver the charging current to the vehicle had signs of overheating. It sort of looked like burn marks. I actually went ahead and opened the casing on one of the relays, trying to get a better look inside. I find it kind of surprising that the legs inside the relay are so thin, you would think they would design them to be thicker, preventing overheating.
Anyways, I decided to attempt a repair. What I did was, remove both power relays and replace them with new ones that I found online. I realize they are the same and I wonder if they won't inevitably fail the same way in the future. Still, I thought it was worth a shot. Alternatively, I thought about adapting a more chunky relay on the board, but the transparent cover of the wall connector leaves no room for a bigger relay.
After soldering in the new relays, it has been working well for a couple of charging sessions at full 48A. I'll continue to test it, to see how long my DIY repair will be good for. If you're interested, I captured a video of how I did the repair and posted it on my YouTube channel here: