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Re: Blink J1772 Cable Repair

Posted: Tue Jul 05, 2016 9:52 am
by GlennD
I have soldered around a half dozen cables. In fact I have been for the last week charging my Mercedes B at 32A with an OpenEVSE and Blink cable combo to burn in the unit. Phil Childs has also soldered his cable.

It does take flux in addition to solder. Only one was burned and that one took scraping the wire bright first. If you have experience soldering it is certainly possible. Since there is several inches of cable in the handle stiffness is not an issue.

Re: Blink J1772 Cable Repair

Posted: Tue Jul 05, 2016 10:03 am
by Valdemar
Does alcohol rosin flux work for this? What wattage is your soldering iron?

Re: Blink J1772 Cable Repair

Posted: Tue Jul 05, 2016 6:45 pm
by GlennD
I am using Weller Soldering Station with Resin 44 solder. It is a very common station. It is hard to get the terminal and wire hot enough to bond. The flux really helps.

Re: Blink J1772 Cable Repair

Posted: Tue Jul 05, 2016 8:23 pm
by Valdemar
GlennD wrote:I am using Weller Soldering Station with Resin 44 solder. It is a very common station. It is hard to get the terminal and wire hot enough to bond. The flux really helps.
Looks like the least powerful Weller station is 40W, I suspect my 25W iron won't be up to the task. Oh well, basic soldering irons are pretty cheap.

Re: Blink J1772 Cable Repair

Posted: Wed Jul 06, 2016 8:43 am
by GlennD
I use a Weller temperature controlled unit with a digital display. I think they are currently just under $200. I like them since there is a full line of tips. In recent years they have gotten very expensive. Tips are now over $5.

Re: Blink J1772 Cable Repair

Posted: Wed Jul 06, 2016 10:19 am
by Valdemar
GlennD wrote:I use a Weller temperature controlled unit with a digital display. I think they are currently just under $200. I like them since there is a full line of tips. In recent years they have gotten very expensive. Tips are now over $5.
While I can certainly appreciate such a tool considering the amount of electronics work I do these days (basically none) it is hard to justify spending that much for something that I will rarely use. A sub-$20 60W iron from Amazon should work just fine, just need to be careful to not overheat the parts and solder.

Re: Blink J1772 Cable Repair

Posted: Wed Jul 06, 2016 7:36 pm
by KillaWhat
I just replaced the cable and J1772 connector on my Blink- Ecotality Project EVSE. (again)

Car Charging Group (Blink) came out and replaced it once for overheat, and then dumbed the EVSE down to 16 Amps.
I couldn't live with that, so I set it back to 32Amps and it ran for almost 2 years.

Then the weirdest thing started happening.
I would find the car not fully charged.
A little investigation led to the discovery of a 160F connection point, and either the car or the EVSE was kicking out.

Only I cannot figure why?

It's a 4 wire system; No temp sensor on the EVSE side, and No temp sensor that I'm aware of in the Cars side of the J1772.

But I'm glad it did so.

Anyway, the Blink OEM was obviously exp. Increasing corrosion.

I had nice a cable and plug assembly that I had purchased when it overheated the first time, and did a quick swap out.

Bought a whole set of security torx at home depot.
(Thought that would be harder.)

Not going to get embroiled in the Solder vs. Crimp debate, but there is a reason they are all crimped.

Re: Blink J1772 Cable Repair

Posted: Wed Jul 06, 2016 8:01 pm
by GlennD
You can either repair the Rema cable or replace it with a Quick Charge Power cable. It really depends on your skill level. Quick Charge supplies a quality cable. It is certainly more money than repairing the crimps but it is much easier.

Re: Blink J1772 Cable Repair

Posted: Wed Jul 06, 2016 9:03 pm
by Valdemar
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.

Re: Blink J1772 Cable Repair

Posted: Wed Jul 06, 2016 9:04 pm
by GerryAZ
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