TESLA 40A Wall Mount, Gen 1 - Tear Down

Repair Notes:  Disassembled charger and rewired for bench testing, see photo below. The conformal coating is very thick, used a utility knife to strip it off the contact points of interest.  Trace circuit for DC High Voltage ( See Rectifier +- , not earth referenced),  Coil +V (TP 1 325V DC, Coil Drive (TP 2 connects to Omron SS Relay pin 6), Omron Relay pin 4 is HV DC ground and Coil drive ground (not earth ground). 

Failed relay symptoms.  Does not charge,  On first power up and handle plug in there is a faint click.  This is the relay closing and then failing the AC Out Sense which shuts off the relay.  NOTE: the TESLA charger does not show any symptoms of this failure. The display is green and the pilot signal is 1khz @ 40A
To simplify testing use EVDoctor Go NoGo pocket tester - https://www.amazon.com/dp/B08X19DN21 
RELAY Repair - The relay is relatively easy to repair as long a the coil is OK,  Remove 2 metric screws on the bottom, (This is hard as they have locktight on the threads you may have to drill them out)   The 4 pins with the nuts on them are the actual internal contact, Remove any burrs and polish with scotch bright or extra fine emery cloth,  put some silicone lube on the actuator cylinder.  Make sure the cylinder moves freely. The relay is a Curtis Albright SW82-312 Coil 240V DC  ~$100,    Alternate  https://howlandtechnology.com  HTI#6231  SW82-353 240DC CO DUST (13223993) $80.00/Unit.  More details here Assembly & parts List http://www.albrightinternational.com/wpcms/wp-content/uploads/2015/07/SW82822.pdf spec sheet http://www.albrightinternational.com/wpcms/wp-content/uploads/2017/06/SW82-Catalogue-Sheet.pdf 

Bench Testing Setup-

Tear down info,  The voltage on the HV Cap is 325V DC. measured across DC Rectifier +-,  NOTE; This is not relative to earth ground.

TP 1 Coil Drive is 325V DC open circuit relative to TP 2 Coil ground, To turn relay on connect TP 1 Coil Drive to TP2 Coil Ground, Relay coil current is limited by a Power resistor.  To turn relay on via the Omron SS Relay connect Relay Enable TP3 (R56) to earth ground (not Coil ground),  Omron SS Relay pin 1 is + 12V.  Do not connect pin 2 to ground

Parts - Control Logic and Pilot Signal Generation,  Main Relay - Curtis Albright SW82-312 240V DC