Thanks for all of the comments - they are much appreciated.
I may not have been clear in earlier posts. As an overriding perspective I want to have a fully code compliant charging solution regardless of how I decide to configure the Wall Connector. I want no risk of having something go wrong due to my negligence or lack of knowledge.
My Clipper Creek HDS-40 EVSE became unreliable due to a problem with the pilot wire sporadically losing continuity, as diagnosed by their tech team. That's why I bought the Tesla Wall Connector, opting for the J1772 connector since it will charge both of my cars using the fully approved Tesla NACS to J1772 adapter. If the Clipper Creek didn't have a problem I'd continue using it as is, without upgrading to the Wall Connector.
Since I had to change to the new Connector I decided that it would great if I could increase my home charging speed, which wasn't an option on the Clipper Creek. So I upgraded the circuit breaker to a 60AMP unit. At the time my friend seemed to believe that this would require no new permit since I was merely upgrading the breaker, not installing any new wiring, and he believed the existing wiring was sufficient.
I asked our local power company if there are any rebates/credits for installing new EV charging equipment, and they said "possibly yes", but since I already have an EVSE installed they weren't sure if I would qualify. They suggested contacting their installation team. While doing that I also contacted a local company specializing in EV installation. They provided a tentative quote of nearly $1,400 to remove my old EVSE, mount the Wall Connector and run a new line from the service connection to my home to the panel in my garage (the picture I posted earlier) to fully comply with local code and inspection requirements. I didn't expect such a high quote, and decided to consult my friend, who removed the EVSE, installed the Wall Connector and wired it with the existing #6 wiring and 40AMP circuit breaker.
Following that, he installed the higher 60AMP breaker today, removing the 40AMP breaker and continued to use the existing wiring. To answer an earlier post the current #6 wire cable contains three wires, two white, one black and a copper ground wire. The second white wire isn't connected to the circuit breaker or to the Wall Connector. The black and white wires are connected to the breaker, and the ground wire is grounded in the panel and all of the wires runs directly to the Wall Connector, and are connected as indicated in the Owner manual describing wiring options.
In the original electrician quote the price of dismounting the EVSE and installing the Wall connector was over $800, including $175 for the permit, the rest for the removal/install using the existing wiring/breaker, which seemed excessive to me. I tried to avoid these costs, and did not believe a new permit was needed since the current wiring met code when installed by a licensed electrician.
Now, reading all of your comments, I'm trying to reconsider my initial thoughts and do this correctly. I believe my choices are:
- Use the newly mounted Wall Connector, reinstall the 40AMP breaker, re-initialize it at 40AMPs and be content to charge at 30miles/hour.
- If I upgrade to a 60AMP service it's likely that the existing wiring will not meet code. To replace it will be expensive since the wall will have to be opened, old wire removed, new wire installed.
- Keep the existing wiring, downgrade the breaker to 50AMPs, which appears to meet code, and have about 25% faster charging.
Frankly, I don't need the faster charging, it's merely a convenience and could be useful. My model Y is a 2023 SR AWD, 279 mile range, which meets 95% of my daily travel needs. For longer trips I SuperCharge on the road. At home I normally charge from 20-80%, varying it to 10-90 on occasion, and infrequently below 10-100% to rebalance the battery pack. The faster charging speeds are welcome, but not madatory.
Just to be clear, regardless of the solution I want to be fully complaint will all codes, rules, etc. Saving money is nice, but doing so while violating code/rules is foolish. My initial addition of the 60AMP circuit wasn't meant to avoid code, or create a potentially unsafe condition, it was merely my misunderstanding of the wiring capacity limits. I also don't want to spend nearly $1,000 if it isn't necessary, and that's why I didn't use an electrician initially.
The above is what I should have written initially, but I was in "adrenaline" mode after connecting the 60AMP service, reinitializing the Setup Process, and seeing the car charge at 48AMPS, so my post was inaccurate and not very clear - sorry for the confusion.
There may indeed be some potential rebate for installing an upgraded EV service, but the rules are complex and not very clear about what is required and what the rebate may be. Clearly an electrician would have more information, but surprisingly I've gotten conflicting information from two firms, both recommended by the local power company.
Until I resolve the wiring issues I'm limiting the charging power on the In Car Charge Menu to 40AMPS, to avoid any potential problems.
So, given all that, what is the best path forward?