Blink EVSE blows out a pin on the Rav4 connector

TonyWilliams · **Posted:** Tue Nov 27, 2012 8:17 am

Link to Schneider EVSE melting and difficult to remove

palmer_md · **Posted:** Tue Nov 27, 2012 5:22 pm

wow, the more I hear about Blink, the happier I am that they do not have any service in my area. Everyone who owns one spends far too much time working on keeping them functional, and the public ones are always down as well.

Sorry to hear that it has damaged the inlet on your vehicle. I hope they can fix it quickly.

Dsinned · **Posted:** Tue Nov 27, 2012 8:11 pm

Tony, when a connector's electrical contact insulation looks melted like that the cause is usually a very high overload current, or perhaps a short circuit abnormal condition. Another possibility is a severe under voltage source condition. Did your circuit breaker trip open to your charging station? What is the output voltage & current rating of the Blink charger you're using? Is it the one on the following list Toyota says is "compatible"?

Please keep us advised on what they say at the dealership, i.e. cost to repair, how long to repair, warranty coverage, etc.

Toyota Approved - RAV4 Original Equipment:
Leviton's Level 2 (240V) 40A, 30A and 16A Toyota Program models and EVR-green series
Panasonic Level 1 Unit that comes with Rav4

Basic Compatability:
AeroVironment Level 2 EVSE-RS
Blink / ECOtality Level 2 Charge Station
Charge Point / Coulomb Technologies CT2000 Series
Clipper Creek CS Series
Eaton Pow-R-Station (Commercial), EV Charging Station (Residential)
Schneider Electric EVlink Indoor Charging Station (EV2430WS)

TonyWilliams · **Posted:** Wed Nov 28, 2012 4:45 am

Blink (approved list) EVSE at 240v 30 amp (7.2kW).

No circuit breaker popped (on a dedicated 40 amp).

Toyota is flying somebody from Michigan to look at the Blink.

Dsinned wrote:

Tony, when a connector's electrical contact insulation looks melted like the cause is usually a very high overload current, or perhaps a short circuit abnormal condition. ANother p;ossibility is a severe under voltage source condition. Did your circuit breaker trip open feeding your charging station? What is the output voltage & current rating of the Blink charger you were using? Is it the one on the following list Toyota says is "compatible"?

Please keep us advised on what they say at the dealership, i.e. cost to repair, how long to repair, warranty coverage, etc.

Toyota Approved - RAV4 Original Equipment:
Leviton's Level 2 (240V) 40A, 30A and 16A Toyota Program models and EVR-green series
Panasonic Level 1 Unit that comes with Rav4

Basic Compatability:
AeroVironment Level 2 EVSE-RS
Blink / ECOtality Level 2 Charge Station
Charge Point / Coulomb Technologies CT2000 Series
Clipper Creek CS Series
Eaton Pow-R-Station (Commercial), EV Charging Station (Residential)
Schneider Electric EVlink Indoor Charging Station (EV2430WS)

nealroche · **Joined:** Fri Dec 07, 2012 7:42 pm **Posts:** 2

Hi Tony
I was amazed by the photos your posted on the J1772 connectors.

I publish a newsletter on EVSE safety and compatibility issues. (my company Gridtest sells test equipment for EV Chargers)

Would you mind if I used your photos for a newsletter? Since I don't know the root cause of the issue, I won't comment on the manufacturers.
Thanks
Neal

Gridtest Systems

TonyWilliams · **Posted:** Fri Dec 07, 2012 8:01 pm

nealroche wrote:

Hi Tony
I was amazed by the photos your posted on the J1772 connectors.

I publish a newsletter on EVSE safety and compatibility issues. (my company Gridtest sells test equipment for EV Chargers)

Would you mind if I used your photos for a newsletter? Since I don't know the root cause of the issue, I won't comment on the manufacturers.
Thanks
Neal

Gridtest Systems

Sure, use all you want.

More pics here

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 IR thermometer testing indicates that another 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 is capable of 40 amps.

The conclusion; a poorly crimped connector on the Blink/Rema charging handle. The following is not my work, nor my pictures:

http://www.mynissanleaf.com/viewtopic.p ... 36#p247736

"Here's the bad pin in the blink handle":

"The copper wire and it's insulation are discolored and embrittled from the heat (the other side still is shiny), so it's quite obvious the crimp is defective. It's not evenly squeezed, is oblong, and the metal of the barrel was smushed in the crimper, which was a low-cost 2-jaw type. The crimps in the other handles I have had apart [Yazaki handle was pictured] are so much better, it's a world of difference."

http://www.mynissanleaf.com/viewtopic.p ... 52#p247652

"Here's the new 70A inlet connected to the same Blink, not it looks almost the same as the Rav4 did in my first test!"

"Here's the Blink handle:"

"I think it's safe to say the Blink has a problem on one side."

"Here's an IR thermograph of the external view of the Blink handle on the Rav4 after 2 hours of charging at 30A:"

nealroche · **Joined:** Fri Dec 07, 2012 7:42 pm **Posts:** 2

Thanks for the info.
Neal

toasty · **Joined:** Sat Nov 17, 2012 3:19 am **Posts:** 17

wow, glad to hear it was fixed

how long did it take them?

TonyWilliams · **Posted:** Wed Jan 02, 2013 9:44 am

toasty wrote:

wow, glad to hear it was fixed

how long did it take them?

About a week. That didn't slow me down too much, as I'm approaching 5000 miles already.

SeattleRav4 · **Joined:** Sat Dec 22, 2012 6:17 am **Posts:** 166

I got brave and tried a Blink station yesterday. While I don't have the Blink card yet so it cost me $2 for the 45 min I was plugged in, it seemed to work just fine.

They will all work just fine... until they don't!!!

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Blink EVSE blows out a pin on the Rav4 connector