GlennD
Forum Supporter
Posts: 1080
Joined: Sun Dec 18, 2011 7:14 pm
Delivery Date: 20 Jul 2013
Leaf Number: 410357
Location: Anaheim

Re: Blink J1772 Cable Repair

Wed Jul 06, 2016 10:02 pm

GerryAZ wrote:KillaWhat,

Maybe the voltage dropped below the minimum threshold for L2 under load as the connection got hotter so the onboard charger shutdown.

All,

Regarding crimp vs. solder: Crimping is faster under assembly line conditions and should be more reliable with properly-adjusted automated crimping tools. Unfortunately, Rema/Blink proved that is not always the way things happen. Soldering makes a good connection when done properly so it is certainly worth fixing a cable at home if the wires and pins are not damaged beyond use.

Gerry


Only one of the cables I have used had a burned connector. That made soldering more work. I had to scrape the cable bright. This was only on one pin. Blink's downgrade is proactive since they had no way of knowing which cables had a bad crimp. Most that I have seen are OK. Soldering is just a precaution. Tony's cable was specially selected to burn up.

I think if I was a technically challenged owner I would just replace the cable and J1772 connector. At the same time you could extend the length. When I upgraded to a 24 ft cable I no longer had to back in my Leaf. It does take years of soldering to get good at it. Tony's cable is a good replacement. And it is available in up to 24 ft at full ratings. Longer derated,
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

wwhitney
Posts: 619
Joined: Sat Jul 17, 2010 10:10 am
Delivery Date: 01 Apr 2011
Location: Berkeley, CA

Re: Blink J1772 Cable Repair

Wed Jul 06, 2016 10:20 pm

Valdemar wrote:One reason why I'm hesitant to just get a replacement cable is that to properly land it on contactor terminals you need to crimp on ferrules on the fine-stranded wire before tightening it with the set screw. I don't want to invest in a good crimper and the cheap ones may produce a crimp that is less reliable than the soldered pins in the Rema handle.

My understanding is that with the right size ferrule, you don't need to crimp it. The ferrule's job is to keep the fine strands contained while the set screw is tightened down. So in effect, the set screw is going to do the crimping for you.

Now, whether you can find the right size ferrule is another question. I don't recall what I did when I replaced my Blink cable; if you find the thread I started a few years ago, it probably says.

Cheers, Wayne

Valdemar
Posts: 2333
Joined: Tue May 10, 2011 10:32 pm
Delivery Date: 09 Sep 2011
Location: Oak Park, CA

Re: Blink J1772 Cable Repair

Wed Jul 06, 2016 10:42 pm

wwhitney wrote:
Valdemar wrote:One reason why I'm hesitant to just get a replacement cable is that to properly land it on contactor terminals you need to crimp on ferrules on the fine-stranded wire before tightening it with the set screw. I don't want to invest in a good crimper and the cheap ones may produce a crimp that is less reliable than the soldered pins in the Rema handle.

My understanding is that with the right size ferrule, you don't need to crimp it. The ferrule's job is to keep the fine strands contained while the set screw is tightened down. So in effect, the set screw is going to do the crimping for you.

Now, whether you can find the right size ferrule is another question. I don't recall what I did when I replaced my Blink cable; if you find the thread I started a few years ago, it probably says.

Cheers, Wayne


On this point, a crimp is likely still better but I wonder if Polaris Grey Connector sleeves are better suited for this as they are specifically designed to be used with set screws, I'm thinking they might be less rigid than your typical ferrule.
'11 SL, totaled
-1CB@33k/21mo, -2CB@53k/33mo, -3CB@68k/41mo, -4CB(41.5AHr)@79k/49mo, -5CB(38.85AHr)@87.5k/54mo
-0CB(66.14AHr)@87.5k/54mo (BBB)
60.5AHr, SOH 94%, 105k miles
9kW Solar

GlennD
Forum Supporter
Posts: 1080
Joined: Sun Dec 18, 2011 7:14 pm
Delivery Date: 20 Jul 2013
Leaf Number: 410357
Location: Anaheim

Re: Blink J1772 Cable Repair

Thu Jul 07, 2016 5:54 pm

I have never seen a Blink cable connected to a charger. All of mine were replaced cables from eBay. They are generally around one hundred dollars plus shipping.

On Tony's dual #12 wires I have used a clamp type connector from McFadden Dale Hardware. It serves two purposes, It makes the connections
neater and the extra mass dissipates heat better.
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

Valdemar
Posts: 2333
Joined: Tue May 10, 2011 10:32 pm
Delivery Date: 09 Sep 2011
Location: Oak Park, CA

Re: Blink J1772 Cable Repair

Thu Jul 07, 2016 6:04 pm

I believe all original Blink cable ends had crimped-on ferrules on them:

Image
'11 SL, totaled
-1CB@33k/21mo, -2CB@53k/33mo, -3CB@68k/41mo, -4CB(41.5AHr)@79k/49mo, -5CB(38.85AHr)@87.5k/54mo
-0CB(66.14AHr)@87.5k/54mo (BBB)
60.5AHr, SOH 94%, 105k miles
9kW Solar

GlennD
Forum Supporter
Posts: 1080
Joined: Sun Dec 18, 2011 7:14 pm
Delivery Date: 20 Jul 2013
Leaf Number: 410357
Location: Anaheim

Re: Blink J1772 Cable Repair

Thu Jul 07, 2016 7:56 pm

OK, A few cables had the ferrals . I just ignored them. The last cable I received had the pilot through a crimp barrel and ferrils..

I have zero interest in owning a Blink charger. In my biased opinion OpenEVSE is much better. The cables after repair are fine. You could certainly add them to a replacement Quick Charge Power cable.
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

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