Tag Archives: Powerxpress

DIY Recall part 2

Yesterday I got a phone call from the electrician about replacing the cable for the Bosch EVSE. It went something like this:

“Hello I’m electrician XYZ calling about that EVSE cable. We can schedule a time for me to come out and swap them out.”

“Oh yeah that cable–I’ve already did the job.”

“Really?”

“Yeah, the instructions were so clear it seemed pretty easy to do. Took me about 15 minutes.”

“It works?”

“Yup right after the swap out I let the car charge for over an hour and nothing blew up.”

“Ok, I may have some paperwork for you to sign.”

Shortly after I got an e-mail from them with the paperwork. The signatures required basically acknowledged that the work was performed to my satisfaction! LOL Sure it was since I did it.

 

DIY Recall

Yesterday my Bosch replacement cables arrived for the Power Xpress EVSE. To my surprise the kit included detailed, clear instructions on how to replace the cables so I did…

The first step was to remove the sticker covering the screws:
Power Xpress panel
The screws are the same square head screws that just about every RV in the world uses which meant that I already had the tool for the job.
Behind the Power Xpress panel
From there its loosen the terminal block screws to pull out the wires, remove the nut to disconnect the ground wire, remove the cable stay, and remove the tension nut at the very bottom.
Once the old cable is out you simply reverse the process to install the new one.
New Cable installed
Finally, plug in the car to test.
New Cable installed
I let the car charge for a good hour to ensure the connections were solid with no ill effects to the EVSE or the car (then I unplugged it and reconnected up the Juicebox LOL since that is my main EVSE).
Total time: about 20 minutes which included trips to/from the basement to retrieve various tools.
Now I await an interesting conversation with the electrician when they call: “Hello we’re calling to perform the cable swap out for your charger.” “Ok I’ve already performed the task, do you need the old cable back?” “What?” “Well the kit came with very clearly illustrated instructions and there was nothing indicating I should wait for the electrician…”

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.

 

Melting?

A few days ago I noticed during my car’s preconditioning that the plug to the charger was getting a bit warm to the touch. Our weather has been pretty mild recently which means that the precondition to 72F shouldn’t be using that much current–just a bit to run the fans, especially near the end of the precondition time. This is very odd since the plug wouldn’t get warm at all back in January when it was <0F out and was preconditioning to 85F.

This warmth raised a red flag in my mind: A similar thing had happened to my coworker. I haven’t mentioned him in a while–the same one with the battery problems at the plant before his car was even delivered. What had happened to him: Over the course of a few weeks his EVSE plug would get warmer with each charge until it eventually got so warm he couldn’t touch it and it was melting the connector on the vehicle side. At the time there was no clear indication if the heat was coming from the vehicle side of the connector or the charger plug. His Ford dealer replaced the car side plug under warranty but the heat and melting continued. This lead to the conclusion that the problem was the EVSE’s plug. Replacing the EVSE solved the heat problem.
Melted Vehicle connector

The reason that I’m a bit concerned about my charger is that we both had the Bosch PowerXPress EVSE installed as part of the deal with our electricity supplier. This unit has various current settings and can be setup for 16A (its default setting for the Volt) all the way up to 30A for cars with quicker chargers. We both had ours setup for 30A service. So far to date mine has never exhibited any kind of heat issue. Looks like I’ll be looking for a new EVSE–been looking for a portable solution for a while and that Clipper Creek LCS-25 looks like a really nice solution.