405 SE EVERETT MALL WAY 2025-06-24

SUPERCHARGER SAFETY MECHANISMS T _ rS L n conductors either between the Supercharger cabinet and Charge Post or inside the EV Connector. The Charge Post Control Board monitors current split between the parallel paths and either reduces current or interrupts charging if the current split become uneven beyond specified thresholds. In some Charge Post variants, the board monitors temperature and controls a coolant pump within the post. Temperature Sensing in Handle The EV connector handle contains a temperature sensor, and the Supercharger system reduces or halts power delivery if the handle temperature exceeds acceptable thresholds. A temperature switch in the handle provides hardware protection as a backup. Charge Port Lock The charge ports on Tesla vehicles lock the connector handle in place at charge session initialization, before any power contactors close or safety checks are performed. The connector handle remains locked in the charge port throughout the charging process. The charge port lock is disengaged when the user presses the EV connector handle button once, at which point power contactors are opened so the connector is no longer energized. Vehicle Contactors and Fuses Two sets of vehicle-side contactors and fuses protect the vehicle battery pack. During the charge session initialization process, the Supercharger system actively matches its output voltage with the vehicle battery pack voltage before the vehicle contactors close in order to prevent surge current due to voltage imbalance. The fuses are integrated into the battery pack. Supercharger Safety Procedures in Operation Tesla's Supercharger system performs redundant safety checks before, during, and after each charge session to ensure safe operation by users and to protect the equipment. When a user plugs a Supercharger EV connector into a Tesla vehicle, the following sequence occurs: 1. The vehicle charge port locks the connector in place. 2. The Supercharger system monitors a proximity line to ensure that the connector is properly inserted into the charge port and locked in position. 3. An analog and digital handshake occurs to ensure robust communication between Supercharger and vehicle. 4. The Supercharger system performs an isolation test and short-circuit test, while simultaneously testing the functionality of DC contactors in the cabinet. 5. To minimize inrush current, voltage at the EV connector is actively matched with the vehicle's battery pack voltage before the vehicle contactors are allowed to close. 6. During the charge session, the Supercharger continuously performs isolation testing and temperature sensing to ensure that the equipment is operating in a safe manner. 7. After the charge session is complete, or if the user interrupts the charge session by pressing the button on the EV connector handle, the entire DC circuit returns to a non-energized state and the vehicle-side charge port lock disengages from the EV connector. Charge Port Lock The EV connector is locked in place when inserted into a Tesla vehicle for charging. There is a small pal on the underside of the connector handle. The charge port of the vehicle has an electronic latch mechanism that engages with this pal to lock the connector in place. If the latch fails to engage (due to incomplete insertion, a broken latch, a charge port failure, etc.), then the digital handshake will fail and charging operation will be prevented. Rev. 1.0, September 2018 CONFIDENTIAL INFORMATION-SHARED UNDER NDA ONLY Page 5 of 8