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

Posted: Wed Feb 06, 2013 12:38 pm
by Ingineer
You cannot "re-crimp" or re-use a crimped connector. It is crimped around the wire, which essentially means crushed. You cannot "un-crush" the pin, so there is no fix. If you had the proper (expensive) crimping tool and new pins, yes, you could shorten the wire and put new pins on. You cannot solder! Soldering wire of this thickness creates a stress concentration down at the solder wicking point that will eventually cause failure. Also, a soldered connection his a higher resistance than a crimped one. And finally, you will have a tough time soldering to a oxidized wire that's been overheated.

-Phil

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

Posted: Wed Feb 06, 2013 3:11 pm
by Herm
Oh come on!.. find me a new pin, give me a set of pliers and will fix it for you. There has a to be source of new pins somewhere. Shade tree car fixing is an old tradition

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

Posted: Wed Feb 06, 2013 3:17 pm
by Ingineer
Herm wrote:Oh come on!.. find me a new pin, give me a set of pliers and will fix it for you. There has a to be source of new pins somewhere. Shade tree car fixing is an old tradition
Did you even bother to read my post? I specifically said you cannot REUSE an OLD (Already crimped) pin. Even if you can find a new pin, You most definitely cannot crimp one of these with a pair of pliers. You need an oxygen-free interface.

Here's the blink pin from the badly-crimped REMA:
Image

This was at least done with a decent tool, and yet it failed. You mean you can do better than this with some pliers?

-Phil

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

Posted: Wed Feb 06, 2013 3:20 pm
by Ingineer
Actually, you need to get it about this good if you want a solid crimp:

Image
(Yazaki's Example)

-Phil

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

Posted: Thu Feb 07, 2013 12:08 am
by DaveEV
evnow wrote:
JimLovewell wrote:I am getting the "twin" chargers. Getting an additional 10KW of chargering for only $1500 is quite the deal compair to the cost of DC charging equipment.
Then why not get the Tesla EVSE ?
I can see a couple reasons not to:

1. Tesla HPC costs $1,200
2. Many homes will not have ability to handle a 80A continuous load without expensive electrical service upgrades.
3. Very rarely need to charge while at home at 240x80A compared to 240x40A, especially if you have a 60-85 kWh Model S. I can see it being more useful on a 40 kWh Model S where one might drive 100 mi, get home and then quickly need to drive another 40-60 mi.
4. If one finds that they do often get home and being able to charge twice as fast would be useful, they can later opt to spend the money on the HPC and service upgrades.

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

Posted: Thu Feb 07, 2013 5:08 pm
by evnow
drees wrote:1. Tesla HPC costs $1,200
What is 1.2k when you are spending north of $70k ? ;)

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

Posted: Thu Feb 07, 2013 7:27 pm
by evnow
JimLovewell wrote:Next, the REMA plug connected to my Blink home EVSE model WE-30CIRE, S/N 101940 running at 16 Amps.

REMA Plug

5.5 °C ambient temperature next to plug & inlet.

17.5 °C AC Power L1, delta T = 12.0 °C
17.4 °C AC Power L2, delta T = 11.9 °C

Leaf Inlet (same Leaf as above)

17.7 °C AC Power L1, delta T = 12.2 °C
15.4 °C AC Power L2, delta T = 9.9 °C
I measured the Blink after about 45 minutes of charging.

Ambient was 53° F and the hottest plug pin was 72° F. Leaf inlet was 73° F. This equates to about 20° F difference or about 10° C, similar to what Jim got above.

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

Posted: Thu Feb 07, 2013 7:33 pm
by jspearman
evnow wrote:
JimLovewell wrote:Next, the REMA plug connected to my Blink home EVSE model WE-30CIRE, S/N 101940 running at 16 Amps.

REMA Plug

5.5 °C ambient temperature next to plug & inlet.

17.5 °C AC Power L1, delta T = 12.0 °C
17.4 °C AC Power L2, delta T = 11.9 °C

Leaf Inlet (same Leaf as above)

17.7 °C AC Power L1, delta T = 12.2 °C
15.4 °C AC Power L2, delta T = 9.9 °C
I measured the Blink after about 45 minutes of charging.

Ambient was 53° F and the hottest plug pin was 72° F. Leaf inlet was 73° F. This equates to about 20° F difference or about 10° C, similar to what Jim got above.
My ambient was 70° F, the hottest pin (on the left) measured 94.6° F. The right side was 88° F.

Blink is coming out to look at my unit. I've asked them to replace the handle with a different model, so we'll see what happens.

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

Posted: Fri Feb 08, 2013 11:29 am
by Ingineer
Basically, if you get a big delta-T (say over 15 degrees F) between the 2 power pins on only a 16A load, you most definitely have a defective crimp!

-Phil

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

Posted: Fri Feb 08, 2013 11:59 am
by evnow
Ingineer wrote:Basically, if you get a big delta-T (say over 15 degrees F) between the 2 power pins on only a 16A load, you most definitely have a defective crimp!
Yes - I'm going to change it out, before I connect to a car with a bigger charger.