DaveinOlyWA
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Re: Blink Blows Out a Contactor Pin (with gory pics)

Tue Nov 27, 2012 9:54 am

How long had it charged before it faulted?
I have to say this is on Toyota. Their BMS,should have detected the issue and shut it down before that happened
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LEAFfan
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Re: Blink Blows Out a Contactor Pin (with gory pics)

Tue Nov 27, 2012 9:55 am

MikeD wrote:Comments:

2) It now becomes clearer why 2 charging ports on a car can be better than one.
+1! I would never buy/lease a BEV without a QC port.
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DaveEV
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Re: Blink Blows Out a Contactor Pin (with gory pics)

Tue Nov 27, 2012 9:58 am

MikeD wrote:So UL listed parts may not be enough to prevent this problem?
UL listing for sure doesn't necessarily account for manufacturing tolerances or foreign debris accumulating in the outlet.

AFCI may not detect the issue shown here - there may not have been any arcing just poor contact. 30A focused on a small area of these small PINs could be the culprit. No wonder manufacturers seem to be hesitant to support 80A on this connector and support for that current was added later...

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Re: Blink Blows Out a Contactor Pin (with gory pics)

Tue Nov 27, 2012 10:19 am

TonyWilliams wrote:I wonder how long it will be before Toyota can even get this part. My car may be out of commission for some time.
Now you get to find out how good or bad Toyota service is.

Some of these inlets / plugs are rated at 70 amps and some are less than that.
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davewill
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Re: Blink Blows Out a Contactor Pin (with gory pics)

Tue Nov 27, 2012 10:27 am

MikeD wrote:1) Where exactly is the proof for your assertion that your Blink is at fault? It matters because there are thousands of public Blink charging stations across the country with perhaps the same J1772 plug make as yours.
That was my thought. Tony seems to blame the Blink, but I'm inclined to blame the newest addition to the equation, his RavEV. Anyway, these parts are standard, and I doubt it points to any widespread problem. Just bad luck for Tony.
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Nubo
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Re: Blink Blows Out a Contactor Pin (with gory pics)

Tue Nov 27, 2012 10:56 am

MikeD wrote:...
4) So everyone ought to inspect any J1772 plug (especially for public charging stations) for deterioration before using? And also inspect your car's J1772 port for deterioration before you plug in to a public charging station lest you damage it (and potentially other car's plugs, etc, etc)?...
A good idea any time you're plugging something in.
I noticed you're still working with polymers.

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Re: Blink Blows Out a Contactor Pin (with gory pics)

Tue Nov 27, 2012 11:17 am

Looking at the first 2 OP images I notice that the un-melted power receptacle to the right of the melted one appears damaged just inside its tip (at least compared to the one at the bottom -- which btw looks like all those in my Blink plug (REM Model: REV-1-30C) ). If true that it is damaged, how could that have happened as a result of the original overheating incident?
Last edited by MikeD on Tue Nov 27, 2012 11:20 am, edited 1 time in total.

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Ingineer
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Re: Blink Blows Out a Contactor Pin (with gory pics)

Tue Nov 27, 2012 11:19 am

All connectors are prone to damage and wear out. Personally, I don't think the J1772 connector is a good enough design for high-utilization at high currents (much over 30A). In this case, Tony was pulling 30A from the blink. I routinely pull this as well with my upgraded Leaf's charger, and the connector definitely gets warm. I regularly inspect it, and occasionally monitor the temperature just to be sure. So far, so good!

It could have just been a fluke, a random defect, or maybe a dead bug in the connector.

Keep in mind very few blinks have been called on to deliver more than 16A or so.

-Phil
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Re: Blink Blows Out a Contactor Pin (with gory pics)

Tue Nov 27, 2012 11:45 am

MikeD wrote:Looking at the first 2 OP images I notice that the un-melted power receptacle to the right of the melted one appears damaged just inside its tip (at least compared to the one at the bottom -- which btw looks like all those in my Blink plug (REM Model: REV-1-30C) ). If true that it is damaged, how could that have happened as a result of the original overheating incident?
I agree. The pin also looks dirty like it was corroded from water. The ground and control pins have a shine absent in the other. Might be the pic angle.
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TonyWilliams
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Re: Blink Blows Out a Contactor Pin (with gory pics)

Tue Nov 27, 2012 11:45 am

Ingineer wrote:
It could have just been a fluke, a random defect, or maybe a dead bug in the connector.

Keep in mind very few blinks have been called on to deliver more than 16A or so.

-Phil

Guys, yes I am jumping on the "Blink is the problem" bandwagon on this, and it may be the (Yazaki?) connector on the Rav4. Obviously, some debri could have been in there since manufacture (sorry, didn't inspect that close).

My Blink charge handle was always noticeably warm at 7.2kW. It failed to start its charge Friday night / Saturday morning, and that should have been a clue, but of course, I was quick to blame that on my lack of familiarity with the Rav4 charge timer (and my wife drove it last, so I ass-umed again that she didn't plug it in correctly... maybe not seated?).

Sunday, I went to the airport with half a tank of electrons (since it didn't charge) and golfing. I charged with a Blink on Coronado Island, which worked fine. I don't know how hot it got, since I had my 12 year old unplug it.

Then, I plugged in Sunday night / Monday morning into my Blink at home for a Range charge (I planned to move motorcycles on a trailer Monday).

The Range charge from near dead (many miles below VLB and Climate Control Limited (CCL)) is what finished it off (about 50kWh).

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