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Blink / Rav4 Blows Out a Contactor Pin (with gory pics)

Posted: Mon Nov 26, 2012 11:27 pm
by TonyWilliams
Update: My Rav4 was fixed under warranty, and I got a Camry rental for a week, also courtesy of Toyota. Of course, I don't think the Rav4 had anything to do with this, and Phil's IR thermometer testing indicates at least one other Blink/Rema handle got quite hot on one pin (opposite to my pin) on a Rav4. Keep in mind, these are only 30 amp Blinks and the Rav4 can take 40 amps.

Phil's conclusion; a poorly crimped connector on the Blink/Rema charging handle.

Sept 3, 2013 - UPDATE: Rema charging handle strikes again and melts the pins on a Nissan LEAF: http://www.mynissanleaf.com/viewtopic.p ... 30#p322830" onclick="window.open(this.href);return false;

More pics here



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

Posted: Mon Nov 26, 2012 11:32 pm
by abasile
I imagine the Blink, even if repaired, will not get much use once your upgraded ClipperCreek CS-40 is set up!

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

Posted: Mon Nov 26, 2012 11:33 pm
by solardude
Simply Inferior.

Plug In. Get Stranded.

Blink

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

Posted: Mon Nov 26, 2012 11:35 pm
by TonyWilliams
I wonder how long it will be before Toyota can even get this part. My car may be out of commission for some time.

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

Posted: Mon Nov 26, 2012 11:44 pm
by surfingslovak
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.
Ouch, that sucks. Looks like Mitsubishi is using a similar inlet on the iMiev, it's likely Yazaki or some other Japanese supplier.

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

Posted: Tue Nov 27, 2012 12:12 am
by TonyWilliams
The Blink can't handle real work. This is a Turtle to 100% "extended range" charge:

Average Power:
7.202 kW

2012-Nov-18

00:57:03 08:10:32 49.909 kWh

Looks like a little cell balancing followed by a top off charge:

10:40:58 11:07:04 0.509 kWh

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

Posted: Tue Nov 27, 2012 12:34 am
by DaveEV
That's not good. Looks like one pin severely overheated, probably due to poor contact.

It'd be interesting to compare high-res pics of other 30A+ rated connectors / inlets...

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

Posted: Tue Nov 27, 2012 4:22 am
by cwerdna
Ouch!

In my mind, the next questions are:
- Is it Toyota's fault?
- Is it the Blink EVSE's fault?
- Are we going to see more issues like this when we see more EVs with 6.6 kW or above chargers which are pulling that much?

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

Posted: Tue Nov 27, 2012 6:36 am
by MikeD
Comments:
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.
2) It now becomes clearer why 2 charging ports on a car can be better than one.
3) So UL listed parts may not be enough to prevent this problem?
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)?
5) Does there need to be AFCI (in the EVSE?) to prevent a worn/defective plug/port from damaging the port/plug?

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

Posted: Tue Nov 27, 2012 8:00 am
by bryan38401
tony the receptacle is avilable at itt/cannon dealers.( ittcannon.com )