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All About EV Chargers

Teardown Siemens Versicharge VG2 30A

5/11/2023

1 Comment

 
We received this Siemens Versicharge VG2 because it would charge and the front panel lights were not correct. The timer "2" was on and pressing the time change button displayed an error.  On further testing there was very erratic light action and you could here the power relay closing. 
Normally this type of problem is caused by the DC power supply so we opened the case and check the power supply. The +5V, +15V & -15V power supplies were OK.   We installed our spare control board and and the problem was not fixed. We installed our spare power and control boards and the problem was not fixed. The problem had to be in the chassis.  We disconnected the orange Pilot wire and tried again,  It worked.  So the problem was in the cable or the J1771 handle. To be sure we left the Pilot wire disconnected and stimulated the charger with our tester.  We used a hammer and a chisel to open the J1772 handle (Destructive)  We found that a small circuit board for the Prox switch took power from the Pilot signal. We cut that orange wire connection and the Versicharge worked normally.  There was obvious corrosion and on the Prox circuit board.  We installed a use J1772 cable and handle and it all worked.   
Moral,  We went on a wild goose chase re the power supply,  Always check the cable and handle first. Note:  Most J1772 handle do not have Prox circuit board and would not have this problem.  Note; The client then told us about water damage to the J1772 handle.
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1 Comment

Mitsubishi Outlander EV Charger Repair

8/25/2022

0 Comments

 

The Mitsubishi Yazaki EV Charger case is quite difficult open. In addition to the screws the cover is glued on with silicon adhesive. We opened this case by cutting off on edge and prying open the case. We found water corrosion on the PCB and were not able to repair this charger. We did learn that this charger, Model 9482A347, is 240V compatible and can charge in 1/2 the time.  

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0 Comments

EV Charger Blink Maintenance Pin for Max Current

8/1/2022

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 Many Blink WE-30 chargers are set to 24A but that can be easily upgraded to 30A to give your charger a 25% speed boost. Go to the Settings screen, press and hold Device Info for 15sec. Then you will be asked for the "Blink Maintenance Pin", Enter 906598 and you will get access to the Maintenance screen, Enter Max Current Setting - 30, and press done. There are other default settings on the Maintenance screen.
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0 Comments

Blink EV Charger Touch Screen Repair

8/1/2022

0 Comments

 
A common problem with the older Blink EV WE-30 Chargers is a failure of the touch screen. The most common problem is a failure of the little black connector for brown/gold ribbon cable that connects to the touch screen.  You need to apply deoxIT to the small black connector on the lower board. Using long nose pliers pull the black latch out ~ 1/16" and that will free the brown flat cable,  Apply deOX it to the cable end and reinsert the cable and push the black latch back in,  Power up and test.  NOTE: you normally do NOT the need to recalibrate the screen. Just wait ~2.5 min and you should be ready to go.
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EVs Are on Their Way to 25M Sales & a $4,700 Retail Price

4/9/2022

0 Comments

 
The world is about to pass another important milestone in electric vehicle adoption: 20 million plug-in vehicles on the road globally, come June, according to BNEF estimates. That’s remarkable growth from only 1 million EVs on roads in 2016.
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Hongguang Mini sells for $4,700

Perhaps most importantly, the models available in China’s EV market show how electric mobility can be very compelling for lower-middle class consumers in emerging markets. The second best-selling EV in China in February of this year was the Hongguang Mini, which retails for just $4,700.
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COUNCIL APPROVES HISTORIC ELECTRIC VEHICLE (EV) MASTER PLAN(April 6, 2022) - 10,000 Vehicles - 97,000 EV Charging Stations

4/8/2022

0 Comments

 
(April 6, 2022) - The Los Angeles City Council today unanimously approved Council President Pro Tempore Mitch O’Farrell and Councilmember Paul Krekorian’s initiative to create an Electric Vehicle (EV) Master Plan, a historic step to electrifying the entire City fleet of over 10,000 vehicles and, for the first time, implement the mass deployment of publicly accessible EV infrastructure citywide.

Today’s actions chart a course to fully electrify the entire City fleet. The initial focus will be to electrify the four largest departmental fleets: Streets LA, LA Sanitation & Environment, the Department of Recreation and Parks, and the Department of Transportation. Additionally, the General Services Department, in coordination with other departments, is instructed to plan for the mass deployment of EV charging stations and infrastructure at more than 600 City-owned facilities, including parks and libraries.

The Department of Water and Power currently projects a need of approximately 97,000 charging stations by the year 2030, underscoring the need for a citywide master plan and implementation in the coming years.

“By starting with public facilities and public-facing infrastructure, we will incentivize the private sector to join us in this effort,” said O’Farrell, who today also introduced a related motion, seconded by Councilmember Kevin de León, to review current contractual workforce standards for EV installations citywide, as part of an effort to ensure that the City employs good workforce standards as it electrifies the transportation sector.

Krekorian, who is also a board member of the County’s Metropolitan Transit Authority (Metro) and the Southern California Regional Rail Authority (Metrolink), is also working to ensure that the City, the County and local transit agencies all coordinate their planning for an EV future.  “This is exactly the work we need to go beyond slogans and bumper stickers to the real work of changing the world, cleaning our air and creating good middle class jobs.”

At a press conference earlier this morning, O’Farrell and Krekorian were joined by a coalition of environmental and labor leaders, including representatives from the Sierra Club, Earthjustice, and the International Brotherhood of Electrical Workers (IBEW) Local 11.
0 Comments

BMWi3 Delphi J1772 Handle Repair & 240V Upgrade

4/1/2022

27 Comments

 
Problem - Does not Charge,  Charger body lights Ok, Proximity Switch not working 
Solution - Open J1772 Handle, replace proximity switch Omron D2HW-BR232M
Opened handle using 5 point start security bit TS15, Removed switch from body,  retest now it is OK,  Best to replace the switch any way. Replace switch.  Test OK, NOTE: This EV Charger was upgraded to 240V operation and now charges in 1/2 the time using our EVDOUBLER.
https://omronfs.omron.com/en_US/ecb/products/pdf/en-d2hw.pdf  ​
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27 Comments

JuiceBox Pro 40 2017 (Brown) Repair - Relay Replacement

1/28/2022

0 Comments

 
Problem - Output power wire overheated burned off and destroyed relay
Repair - Completely dissemble JuiceBox. Wash with soap and water, try to get the smell out, Cut back wires, Crimp on new lugs, install new relay, connect wires, install pcb, reconnect, test OK

 NOTE:  The cause of this problem was loose power cable terminal screws. We see occasionally this in all makes of EV Chargers, We use special care in installing the power cables and tightening the screws,  
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0 Comments

Teardown Hyundai EVSE Repair - Replace J1772 Cable - ref 220112

1/16/2022

24 Comments

 
Problem J1772 Cable Defective
Repair Process
Open case with wide chisel and small sledge hammer (2lb),  Confirm EV Charger works (using EV Doctor Go NoGo Tester),  Found the  ‘Clip in Connector is damaged’.  Remove display & PCB, remove ‘Clip in Connector’.  
Solder in preowned J1772 cable.
NOTE putting the PCB back in is very tight because J1772 cable is in the way, Install nut last
Seal case with epoxy, Re test
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24 Comments

Teardown Toyota Prius G9060-47190 EVSE Repair - Will not Charge, Cable/Handle Repair, No lights

1/9/2022

32 Comments

 
Toyota Prius G9060-47190 Teardown 
Click Here Teardown Toyota Prius G9060-47190  and  ​Click Here for Additional Photos
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