Toyota Rav4 EV Forum

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 Post subject: Re: Cannot charge
PostPosted: Sun Dec 13, 2020 3:07 am 
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Joined: Mon Aug 07, 2017 4:55 pm
Posts: 243
Location: Duvall, Wash.
(the EVSE links in this post, except OpenEVSE, are put there by the forum software and do not have my endorsement)

Everybody's got their favorite EVSE (and do use 'EVSE', rather than 'chrger', it'll save a lot of confusion).

I have a three-year-old OpenEVSE and love it. In the last six months, I bought two more. It has evolved and I'm not sure I like the new clear cover, as there's a white LED inside that turns the EVSE into a nightlight. I have one installed in a remote carport, and it worked out OK to have that nightlight effect, but I would need to disable it or find a software solution to turn it off if I had it installed at my house.

OpenEVSE = it's open (software, hardware, schematics). Good support. Great hardware in the versions made in the last five years.

It can be purchased as a DIY kit, or assembled; I've purchased all three of mine assembled, due to time constraints. $500 plus shipping.

If you buy the Advanced version, it has wi-fi. You can do scheduled charging (I am not currently using this feature), and you have to use your PC or phone to do that, you can't program it from the front panel. Install on a 50A circuit and it'll do 40A charging to a RAV4EV.

(last I checked, the built-in webserver still didn't do https, although it was scheduled to be upgraded fairly soon. If you're security anal, this is a consideration.)

_________________
Regards,
Al Savage
2014 Rav4 EV, Shoreline Blue Pearl, #2609, first use 04Jun2014, 49k miles (Aug2017), OpenEVSE 40A. First DU replacement May2018 59k.
2018 Model 3 LR AWD, blue. 9.6kw solar
1999 E300 on B100 (sold Sep2018)
http://nissandiesel.dyndns.org


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 Post subject: Re: Cannot charge
PostPosted: Sun Dec 13, 2020 4:59 am 
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Joined: Thu Sep 05, 2019 7:38 pm
Posts: 25
asavage wrote:
OpenEVSE = it's open (software, hardware, schematics). Good support. Great hardware in the versions made in the last five years.

It can be purchased as a DIY kit, or assembled; I've purchased all three of mine assembled, due to time constraints. $500 plus shipping.

If you buy the Advanced version, it has wi-fi. You can do scheduled charging (I am not currently using this feature), and you have to use your PC or phone to do that, you can't program it from the front panel. Install on a 50A circuit and it'll do 40A charging to a RAV4EV.


Awesome, great info -- thanks @Al Savage! I'm currently using one of those $200 Chinese EVSE that I got on Amazon awhile back, so maybe you get what you pay for. I will look into getting a prebuilt OpenEVSE.


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 Post subject: Re: Cannot charge
PostPosted: Sun Dec 13, 2020 6:00 pm 
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Joined: Sun Sep 03, 2017 3:46 pm
Posts: 82
Location: Ukraine
asavage wrote:
Unfortunately, tech26 didn't post the pictures for that fuse replacement where we can see them. I reached out to him via email a while back, hoping to get those pics, no dice.
My experience with electronics fuses is that they very rarely blow for no reason:(

The RAV4 EV onboard charger is fairly expensive when they come up for sale used (I think I saw one on eBay last week for $1500). I have it on good authority that the Model S Gen 1 onboard charger can be substituted, but its firmware must be re-flashed to work with the RAV4 EV, and it's hard to do that "in the wild".

I did not make a Diagnose for this car, but described possible options. Since I'm not aware of the actual diagnostic results (DTC, Data Stream, etc.).
In my practice, approximately 3-5% of all RAB4EV malfunctions are caused by a Charger malfunction. In several cases, replacing this fuse was sufficient http://alflash.com.ua/2020/images/charger_fuse.jpg
Unfortunately, sometimes this was not enough.
I know of one case confirming the possibility of installing a Tesla S Charger in RAV4EV.


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 Post subject: Re: Cannot charge
PostPosted: Mon Dec 14, 2020 10:42 pm 
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Joined: Wed Aug 13, 2014 8:30 pm
Posts: 283
Location: San Diego Co
I have photos of the charger fuse location and some steps along the way. I will say that it was necessary (and arduous) to completely remove the on-board charger from the Rav4. Then the top cover is removed and several other connections are removed. Finally you are able to remove the charger housing from the base plate. But there are still more screws/connectors to remove the insulation cover over the fuses without damage, and finally test and replace the fuses.

It is no easy task, and now that I know how to do it, it would likely still take 6 to eight hours to complete start to finish. Below is a link to some photos that may be helpful.

https://photos.app.goo.gl/kTX7tUQfBnt8aVAZ9

_________________
8/12/14 RAV4 EV #3008, Blizzard Pearl
9kW Solar Electric System
SDGE TOU metering
OpenEVSE 40 amp

"Aquaponics...solar-powered nanotechnology that produces fresh vegetables and meat, while purifying water..." - Rick Op, Houston Texas.


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 Post subject: Re: Cannot charge
PostPosted: Tue Dec 15, 2020 1:17 am 
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Joined: Thu Sep 05, 2019 7:38 pm
Posts: 25
I spoke with the Toyota service manager and he thinks my charging cable shorted something in the charging connector and that system error code is going to prevent charging until it's reset, which they will do for me when I bring it in.

They recommend I don't plug my existing cables again to prevent this in the future. This seems suspect to me since both the original 120V cable that came with the car and the aftermarket 240V cable suddenly causes a short when plugged in? Hmm...that seems like too much if a coincidence they can both fail at the same time. I have a feeling something else is going on here. My next option is to order a new EVSE and see whether that changes anything.


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 Post subject: Re: Cannot charge
PostPosted: Tue Dec 15, 2020 1:41 am 
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Joined: Sun Sep 03, 2017 3:46 pm
Posts: 82
Location: Ukraine
10basetom wrote:
I spoke with the Toyota service manager and he thinks my charging cable shorted something in the charging connector and that system error code is going to prevent charging until it's reset, which they will do for me when I bring it in.

They recommend I don't plug my existing cables again to prevent this in the future. This seems suspect to me since both the original 120V cable that came with the car and the aftermarket 240V cable suddenly causes a short when plugged in? Hmm...that seems like too much if a coincidence they can both fail at the same time. I have a feeling something else is going on here. My next option is to order a new EVSE and see whether that changes anything.
As for me, his explanations are very unconvincing.
Each malfunction must be documented.
What error code is not erased he told you?


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 Post subject: Re: Cannot charge
PostPosted: Tue Dec 15, 2020 1:45 am 
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Joined: Mon Aug 07, 2017 4:55 pm
Posts: 243
Location: Duvall, Wash.
Thanks for posting those, much better than nothing, and gives a sense of the overall job.

I searched and didn't find a previous post here by you about your having to replace the onboard chrger's fuse; how long ago was that, and did it only occur the once?

Perhaps this is one of those units where the fuse truly protects against a rare event. It's a shame Tesla designed the fuses in the DC-DC Converter and onboard chrger to be so bloody difficult to replace, since at least on the DC-DC it's a very common failure (due to the AC Compressor or heater going overcurrent).

_________________
Regards,
Al Savage
2014 Rav4 EV, Shoreline Blue Pearl, #2609, first use 04Jun2014, 49k miles (Aug2017), OpenEVSE 40A. First DU replacement May2018 59k.
2018 Model 3 LR AWD, blue. 9.6kw solar
1999 E300 on B100 (sold Sep2018)
http://nissandiesel.dyndns.org


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 Post subject: Re: Cannot charge
PostPosted: Tue Dec 15, 2020 1:50 am 
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Joined: Sun Sep 03, 2017 3:46 pm
Posts: 82
Location: Ukraine
dstjohn99 wrote:
I have photos of the charger fuse location and some steps along the way. I will say that it was necessary (and arduous) to completely remove the on-board charger from the Rav4. Then the top cover is removed and several other connections are removed. Finally you are able to remove the charger housing from the base plate. But there are still more screws/connectors to remove the insulation cover over the fuses without damage, and finally test and replace the fuses.

It is no easy task, and now that I know how to do it, it would likely still take 6 to eight hours to complete start to finish. Below is a link to some photos that may be helpful.

https://photos.app.goo.gl/kTX7tUQfBnt8aVAZ9
Thanks for the pictures.
What were the symptoms of a fuse malfunction on this car?


Last edited by alflash on Tue Dec 15, 2020 2:56 am, edited 1 time in total.

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 Post subject: Re: Cannot charge
PostPosted: Tue Dec 15, 2020 2:30 am 
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Joined: Thu Sep 05, 2019 7:38 pm
Posts: 25
alflash wrote:
As for me, his explanations are very unconvincing.
Each malfunction must be documented.
What error code is not erased he told you?


I will be sure to ask for exact error codes when I bring car in this week.

Thank you @dstjohn99 for posting these photos. I asked the service manager whether he can point the EV technician to this thread in case it helps any but they have a policy against that so no go.


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 Post subject: Re: Cannot charge
PostPosted: Tue Dec 15, 2020 3:00 am 
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Joined: Sun Sep 03, 2017 3:46 pm
Posts: 82
Location: Ukraine
10basetom wrote:
alflash wrote:
As for me, his explanations are very unconvincing.
Each malfunction must be documented.
What error code is not erased he told you?
I will be sure to ask for exact error codes when I bring car in this week.

Thank you @dstjohn99 for posting these photos.
I asked the service manager whether he can point the EV technician to this thread in case it helps any but they have a policy against that so no go.

Ok.
Is it really interesting for someone to read about their defect / omissions? Surely they are not interested. ;)
Their policy does not recommend getting acquainted with the practice of repairing and diagnosing a RAV4EV car? At least strange.


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