GlennD
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Blink J1772 Cable Repair

Sat May 24, 2014 12:18 pm

I have been buying supposedly new Blink cables on Ebay. This one was obviously a used one changed out for overheating. The brown wire looked overheated and it took a lit of flux to get a good connection.

Here is a few photos. I assume you will know what you are doing so no step by step.

Image

Image

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Image

Image

Image
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pchilds
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Re: Blink J1772 Cable Repair

Sat May 24, 2014 2:14 pm

Thanks Glenn, I should have took pictures when I fixed my SPX cable. Where did you get the 5 point security bits?
2011 LEAF, gone,
2012 RAV4 EV,
2015 Model S 85D,
Solar PV 5.25 kW system.

GlennD
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Re: Blink J1772 Cable Repair

Sat May 24, 2014 6:38 pm

pchilds wrote:Thanks Glenn, I should have took pictures when I fixed my SPX cable. Where did you get the 5 point security bits?


I had to buy the whole 1/4 inch set from Ebay. I forget the cost but it was between 20 to 30 dollars. Such a waste since I really only need 1 bit.
2012 Cayenne Red SL traded for:
2013 Pearl White SL Premium
Traded for a Cirrus White 2014 Mercedes B (totaled)
2016 Urano Gray eGolf SEL w/ drive assist

GlennD
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Re: Blink J1772 Cable Repair

Sun May 25, 2014 8:57 am

Phil, I looked up the set.

Assuming the connector is not melted repairing it is far cheaper than replacing it.

http://www.ebay.com/itm/5-POINT-TORX-ST ... 563dd8a819
2012 Cayenne Red SL traded for:
2013 Pearl White SL Premium
Traded for a Cirrus White 2014 Mercedes B (totaled)
2016 Urano Gray eGolf SEL w/ drive assist

TimLee
Posts: 2810
Joined: Thu Jan 20, 2011 9:40 am
Delivery Date: 17 May 2011
Leaf Number: 2026
Location: Chattanooga, TN

Re: Blink J1772 Cable Repair

Wed Sep 03, 2014 6:19 pm

Ingineer pointed out in separate thread that when the crimp has developed oxidation it is impossible to solder adequately.
And that soldering this size conductor creates stress concentration that will ultimately cause failure even if you were starting with new stuff. Plus the soldered connection runs hotter than a crimped connection that is properly crimped.
See viewtopic.php?f=26&t=10749&start=320#p265233" onclick="window.open(this.href);return false;.

This may be cheap but seems like a bad idea if you trust the input from Ingineer.
And unfortunately some people are sending other people to this bad idea.
Last edited by TimLee on Tue Jul 05, 2016 10:00 am, edited 1 time in total.

Tim Lee
Chattanooga, TN

Man. Date: 03/10/11, VIN # 2026
Delivered 05-17-2011
Blue Ocean, 2011 SL-eTec

GlennD
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Re: Blink J1772 Cable Repair

Wed Sep 03, 2014 7:28 pm

Using external flux it is certainly possible to solder the pins. As far as stress on the wire the pins are at least eight inches away from the cable's stress relief. There is no way the cable will put stress on the pins.

If you feel this is not an acceptable repair by all means replace the cable. Currently on Ebay you can get a brand new 16 ft Yazaki 30A cable for $105 plus $20 for shipping. From Quick Charge Power you can get a 25 foot 40A cable for $204 shipped.
2012 Cayenne Red SL traded for:
2013 Pearl White SL Premium
Traded for a Cirrus White 2014 Mercedes B (totaled)
2016 Urano Gray eGolf SEL w/ drive assist

TimLee
Posts: 2810
Joined: Thu Jan 20, 2011 9:40 am
Delivery Date: 17 May 2011
Leaf Number: 2026
Location: Chattanooga, TN

Re: Blink J1772 Cable Repair

Thu Sep 04, 2014 3:27 am

You disagree with Ingineer :shock: :? :shock: :?

Tim Lee
Chattanooga, TN

Man. Date: 03/10/11, VIN # 2026
Delivered 05-17-2011
Blue Ocean, 2011 SL-eTec

MikeD
Posts: 584
Joined: Thu Jun 24, 2010 6:14 am

Re: Blink J1772 Cable Repair

Thu Sep 04, 2014 5:29 am

Can anybody say what metal(s) the coupling pins are made of? Are they silver plated copper or perhaps nickel plated copper (or something else)? I saw a technical advisory a couple of years ago that seemed to suggest both have been used by J1772 manufacturers, but that the former was much preferred over the latter for unstated reasons. Can this be part of the problem?

If you look at crimps/connectors used for 50a electric range cords/plugs/receptacles, the question arises as to what does it take to have a sufficiently sound electrical termination when currents are, say, no more than 30a as for these Blink EVSEs?

It also seems clear that mechanically mating electrical plugs/jacks wear out over time, suffer corrosion, etc so what is necessary to prevent/mitigate overheating problems in this area?

GlennD
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Re: Blink J1772 Cable Repair

Thu Sep 04, 2014 7:15 am

TimLee wrote:You disagree with Ingineer :shock: :? :shock: :?


ABSOLUTELY! He is very knowledgeable but no one is always right.
2012 Cayenne Red SL traded for:
2013 Pearl White SL Premium
Traded for a Cirrus White 2014 Mercedes B (totaled)
2016 Urano Gray eGolf SEL w/ drive assist

pchilds
Posts: 416
Joined: Sun Jun 17, 2012 12:14 am
Delivery Date: 31 Jul 2011
Leaf Number: 006141
Location: SoCal

Re: Blink J1772 Cable Repair

Thu Sep 04, 2014 10:35 am

Of all the cables I have tested, the Rema cable, that I soldered, runs the coolest. At 32 amps the temperature was 101 f, after 1 1/2 hours.
2011 LEAF, gone,
2012 RAV4 EV,
2015 Model S 85D,
Solar PV 5.25 kW system.

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