Blink J1772 Cable Repair

[GlennD]

I have been buying supposedly new Blink cables on Ebay. This one was obviously a used one changed out for overheating. The brown wire looked overheated and it took a lit of flux to get a good connection.

Here is a few photos. I assume you will know what you are doing so no step by step.

[pchilds]

Thanks Glenn, I should have took pictures when I fixed my SPX cable. Where did you get the 5 point security bits?

[GlennD]

Thanks Glenn, I should have took pictures when I fixed my SPX cable. Where did you get the 5 point security bits?

I had to buy the whole 1/4 inch set from Ebay. I forget the cost but it was between 20 to 30 dollars. Such a waste since I really only need 1 bit.

[GlennD]

Phil, I looked up the set.

Assuming the connector is not melted repairing it is far cheaper than replacing it.

http://www.ebay.com/itm/5-POINT-TORX-ST ... 563dd8a819" onclick="window.open(this.href);return false;

[TimLee]

Ingineer pointed out in separate thread that when the crimp has developed oxidation it is impossible to solder adequately.
And that soldering this size conductor creates stress concentration that will ultimately cause failure even if you were starting with new stuff. Plus the soldered connection runs hotter than a crimped connection that is properly crimped.
See http://www.mynissanleaf.com/viewtopic.p ... 20#p265233" onclick="window.open(this.href);return false;.

This may be cheap but seems like a bad idea if you trust the input from Ingineer.
And unfortunately some people are sending other people to this bad idea.

[GlennD]

Using external flux it is certainly possible to solder the pins. As far as stress on the wire the pins are at least eight inches away from the cable's stress relief. There is no way the cable will put stress on the pins.

If you feel this is not an acceptable repair by all means replace the cable. Currently on Ebay you can get a brand new 16 ft Yazaki 30A cable for $105 plus $20 for shipping. From Quick Charge Power you can get a 25 foot 40A cable for $204 shipped.

[TimLee]

You disagree with Ingineer

[MikeD]

Can anybody say what metal(s) the coupling pins are made of? Are they silver plated copper or perhaps nickel plated copper (or something else)? I saw a technical advisory a couple of years ago that seemed to suggest both have been used by J1772 manufacturers, but that the former was much preferred over the latter for unstated reasons. Can this be part of the problem?

If you look at crimps/connectors used for 50a electric range cords/plugs/receptacles, the question arises as to what does it take to have a sufficiently sound electrical termination when currents are, say, no more than 30a as for these Blink EVSEs?

It also seems clear that mechanically mating electrical plugs/jacks wear out over time, suffer corrosion, etc so what is necessary to prevent/mitigate overheating problems in this area?

[GlennD]

You disagree with Ingineer

ABSOLUTELY! He is very knowledgeable but no one is always right.

[pchilds]

Of all the cables I have tested, the Rema cable, that I soldered, runs the coolest. At 32 amps the temperature was 101 f, after 1 1/2 hours.