Tag Archives: Melting

The next chapter in the melting saga

If you’ve been reading this blog a while you may recall one of the stories of my coworker’s car when his charge plug melted. For a refresher here is a picture of the plug:
Melted Vehicle connector

After getting the vehicle side connector replaced twice he finally had Bosch come out and replace the vehicle side wiring of his Power Xpress EVSE. Since then we’ve both been contacted about a recall of the Power Xpress unit. Since then I’ve received a phone call from Bosch stating that parts are finally available and I’ll be contacted by an electrician to swap out the cables.

The funny thing is that last week I received an e-mail with a tracking number from Bosch. Today that package was delivered:
Power Xpress harness

A shiny new wiring harness for my Power Xpress unit (Note that I have not been charging my FFE with the Power Xpress since my coworkers problems with it and about the same time I had noticed that the handle was starting to get a little warm in the morning after a charge. I’ve been making due with either the Juicebox or the Clipper Creek EVSE’s that I have).

What is more interesting about this shipment is that it comes with very clear instructions on how to swap out the wiring harness. I may just do the swap myself and when the electrician calls just tell them that I’ve already performed the task. (The procedure is pretty simple: remove a panel, disconnect the old wires, unscrew the strain relief, remove the old wire, insert the new wire, connect wires, tighten strain relief, and replace the panel.)

Taking a close look at the plug:
Power Xpress plug
Oooh all shiny: These contacts are silver coated. Silver coated contacts don’t corrode. The old plug is all copper which can oxidize and introduce some resistance. Given that 240V at ~30A goes through there even a small amount of resistance here will generate some heat.

Now I’m awaiting a phone call…LOL.

 

A PowerXPress “recall”?

Interesting, I got the following note in the mail from Bosch:
PowerXPress note
Here is the text:

Our records indicate that you are using your Power Xpress to charge an electric
vehicle(s) with a charging system that operates at 30A or higher. Recent
incidents have occurred in which customers have expressed concerns related
to the performance of the Power Xpress while charging at 30A or higher. Some
consumers have reported incidences of sticking or melting within the connection
between the charging station coupler and the vehicle inlet.
The. Power Xpress is designed to charge vehicles up to 32A. A new cable/coupler
assembly has been designed to address the customer concerns while charging
at 30A or higher. In an effort to secure your complete satisfaction, Bosch will
upgrade your Power Xpress with a new cable/coupler assembly — completely at
your convenience, and at our cost.
The division of SPX Corporation that originally designed and sold the Power
Xpress became part of the Bosch group of companies and now operates as Bosch
Automotive Services Solutions Inc. (“Bosch”). Therefore, Bosch will be addressing
your charging needs going forward, including the upcoming interaction with you
regarding your charging station.
A Bosch customer service representative will be contacting you within the next
30 days in order to arrange for this upgrade. We will coordinate with you to have
a Bosch certified electrical contractor visit your installation at a time of your
choosing to complete the exchange of the coupler and cable. Because the Power
Xpress was designed for field replacement of the cable/coupler assembly, this
repair will take less than one hour and will not disturb your installation or its
environment in any way. A licensed electrician will detach the existing cable/
coupler from the unit and simply install the new one.
Should you no longer own your Power Xpress, we ask that you forward this
message along to the new owner if possible, or provide the new owner’s contact
information if available.

If you have any questions in advance of our contacting you,
please call Bosch at +1 888 823-9877.
Bosch Automotive Service Solutions

This is interesting! You may remember that my coworker suffered from this very problem. A technician eventually did replace the cable in his unit at no cost. The issue must have happened to more than a few EV owners for Bosch to issue this recall.

 

More on that melting..

Back in May I had mentioned that my coworker noticed the handle of the Bosch EVSE he was using was getting warmer and warmer (see post here).

After he had his EVSE and the charge connector in the car replaced all was well..or so he had thought.
Melted Vehicle connector

Above is his first vehicle connector before being replaced.

Changing out the EVSE eventually fixed the problem but not before the 2nd vehicle connector also suffered some damage. Unfortunately his dealer did not feel the need to replace the 2nd damaged unit.

Fast forward to last week: He gets in his car to go to work and is greeted by a strange prompt in the car: “Am I still plugged in?” Not thinking much about it he dismissed the prompt and proceeded with his commute. At work everything went nuts: The dash board started flashing many errors and warnings, including the dreaded “Stop Safely Now” message and the car quit. He called Ford’s Roadside Assistance for a tow–which was very efficiently handled, he got text messages to his phone indicating which tow company was coming and when..if only other Ford operations worked so well. The tow truck driver even asked to see the owners manual to clarify how to tow the car.

Once the car was at the dealer he prepared for the worst (since most of his experiences with the dealer have been less than satisfactory). They replaced the charge plug and harness, the LED ring and the 12V battery in the car (With the damage to the old plug the car was left in a state where it thought it was plugged in and thought it wasn’t plugged in thus keeping the 12V electronics in the car alive enough to drain & damage the 12V battery which is why the car freaked out). The dealer even kept the car overnight after all the fixes were done “for observation” to ensure that all was well and working before returning it.

Happily after a weekend of putting 50+ miles on the car it seems to be back to its quirky self again, and plugging a charger in is no longer a delicate operation…

Here is hoping this is the last story I hear from him about car malfunctions! (He is now investigating a completely new EVSE.)