Start a new topic

Not charging - EVSE begins reset cycle immediately after relay switches.

I recently installed my Open EVSE and have yet to successfully charge my 2024 Toyota Rav4 Prime. It's on a 50amp breaker and as far as I can tell my vehicle's charger can run a maximum of 32amps.


What happens is I plug it into the vehicle, the EVSE recognizes it is plugged in and needs a charge, I hear the relay switch and then the EVSE turns off, restarts and continues to turn off and restart (not getting past the initial loading screen) until I unplug it and the relay closes. It does appear that the vehicle is still being charged during this restarting time but I have yet to keep it plugged in to verify. I say that because I don't hear the relay switch until I unplug the vehicle, and the vehicle dashboard shows a "time until charged" (which is basically the same time remaining as with the 6amp 110v charger).


Here is what a log looks like until it abruptly stops and turns off/restarts: $AT 02 02 32 0700^37 $SY^2E $OK 5 6 0^33 $SY^2E $OK 5 6 0^33 $SY^2E $OK 5 6 0^33 $SY^2E $OK 5 6 0^33

relayCloseMs: 100

relayHoldPwm: 255


Every time I have tried it looks like it abruptly turns off at the same time, right after the relay parameters are shown.


Troubleshooting: 

So far what I've done for troubleshooting is 

1. plugged the vehicle in fully charged - EVSE recognizes vehicle is plugged in but doesn't need charge and nothing strange happens.

2. changed maximum amperage settings up to 40amps and down to 6amps, still have same problems charging.

3. Turned off all EVSE safety checks, still have same problems.




Was this a kit of factory assembled station? If this is a kit please post pictures of inside the station. 


This can happen if low voltage signal wires are mixed with the relay/relay coil wires as there is a tremendous amount of noise when the relay closes. Keeping all the signal wires neatly bunched low in the enclosure away from high voltage wires will allow the station to operate normally.

Thank you for your reply.


Yes it seems that was exactly the problem, I built the kit and had to rewire it twice to get the signal wires as far from the high voltage wires as possible. After the fix it still went into a restart cycle once (about a minute into charging...) but I think that was a one-off problem. I'll report back if it happens again.


For future people who may have this problem, below are pictures of the setup that didn't work, and that did work.  


This was how I initially built it with the restart cycle problem. The ground wire was right close to the signal wires, so I moved that but it didn't fix the problem. I'm not sure if the ground needs to be distanced from the signal wires.

image


Below wiring also didn't work, even though the signal wires were much further from the high voltage ones:

image


Finally this below setup worked, it's hard to tell the difference between the last one with photos but I just gave the signal wires as much distance as possible (difficult since they're coming off the CTs that are directly around the high voltage wires) and taped them to the back of the housing:

image


Another photo of how it should look (or at least how it looks while working for my setup):

image




Glad to have the charger finally working. Paired with PVs we're driving off the sun's power. Thanks again for the EVSE support. I'm slowly learning more about coding and how it all works.
Login or Signup to post a comment