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Charger boot looping when Wi-Fi module plugged in
OpenEVSE Support
The most common reason for this behavior is running low voltage wires for coils, display, WiFi, etc too close to high voltage wires. The wires that trigger the relay are especially noisy. Can you post pictures from inside your station?
any suggestions ?
OpenEVSE Support
The low voltage wires for the coils are running right across the top of the relay. When the relay triggers there is a huge amount of noise. I would guess the reboot happens right when the relay is triggered.
Please take a look at the diagram here:
https://github.com/OpenEVSE/OpenEVSE_PLUS/blob/master/OpenEVSE_PLUS_v5.5/Advanced_2024.pdf
And the build guide here:
https://openevse.dozuki.com/Guide/Current+-+v5.5-v5.6+OpenEVSE+Advanced/26
Both coil wires should be rerouted low in the enclosure near the ground plate. We would also suggest Ferrules on Your AC input and EV cable power lines.
THank you for the guidance, ill cleanup the wire and give it a shot, however, worth noting the wiring as is does not cause a problem. Its only when the wifi module is plugged in does the bootloop happen.
Ive cleanup my wiring as shown below. The bootlooping still occurs only when the wifi module is plugged in. New video below shows this.
https://www.youtube.com/shorts/_pYvPdGyFv8
OpenEVSE Support
Hi Rob we sent a replacement WiFi module.
The wire routing is still concerning. The low voltage signal wires from the current coils are now tie wrapped to the high voltage wire exiting the relay. The whole point was to create separation between the low and high voltage components/wires. The wires from the coils should be routed alongside the orange pilot wire as close to the metal plate as possible.
Understood, I bought some ferrules for the high voltage cabling so when I install those I will adjust the low voltage wiring accordingly.
New board behaves the same way , controller issue ? Should I send the lastest wifi board back ?
OpenEVSE Support
I can not come up with any failure scenario that would make the controller behave that way, but we can send a replacement and once we figure out what is causing the problem you can send the good parts back.
I have reviewed the picture again. What are the red and blue wires? This should be for a GFCI coil with self test loop. There are only 2 wires connected and its not clear where they go.
Those wires go to the self test coil, should i get those close to the base plate ?
OpenEVSE Support
Self test of what? I can only see a single coil the current measurement coil. The red and blue wires are currently connected to the GFCI coil sense inputs, not the self test outputs.
I can not see the GFCI coil. If there is no GFCI coil... How can you self test GCFI?
Here is the build guide that shows both coils and how they connect.
https://openevse.dozuki.com/Guide/Current+-+v5.5-v5.6+OpenEVSE+Advanced/26?lang=en
Here is a PDF connection diagram.
https://github.com/OpenEVSE/OpenEVSE_PLUS/blob/master/OpenEVSE_PLUS_v5.5/Advanced_2024.pdf
Rearrange both coils to be close to how they are shown in the guide, still no luck.
Rob Reason