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This is the second time this has happened on my charger with this car. The first time around the OpenEVSE time was kind enough to provide me a replacement charging cable because it appeared that there was no continuity on the pilot wire. I haven't tested it yet again but I assume its the same issue ( I will test to confirm ). The question is, since this has happened twice, what's the real problem? I doubt that I have 2 bad cables.

The symptoms were the same. I plug the charger into the car and the neither the car or the charger indicate anything is connected. I unplug the cable, then restart the the both components on the charger. Plug the cable back in and everything is working. But this process only worked once. Last time I was able to "apply the fix" 3 times before it didn't work anymore.

Any suggestions on other troubleshoot besides check for continuity on the pilot wire? There has to be a problem somewhere else that is causing this.

The UI doesn't currently report any errors It reports ready  with a smoothed current of 17A (I use diversion). I did flip it over to manual and there was no change, as expected because it doesn't see a car connected The UI does report a history of  10 no ground errors and 2 stuck contact errors. I'm pretty sure those are from testing the last time I had this issue. I don't see a way in the UI to clear those error to start with fresh counters. Is that possible?

I've attached an export of the data from the EVSE for you

I've done some more testing and the results are... odd.

TIL: the safety counters are stored on the EVSE controller and not the wifi component. Do a reset of the wifi board doesn't clear those counters

I have continuity on the CP wire. And I have found a procedure to get it working again.

1. Unplug charger

2. Disconnect WiFi/TFT display

3. Test continuity on CP wire

4. Plug handle into car

5. Plug in charger

6. Wait for replay to active by EVSE controller

7. Unplug charger

8. Reconnect WiFi/TFT display

9. Plug in charger

This procedure usually gets me 1 or 2 insertions of the handle before I have to repeat it.

This makes no sense to me, which makes it feel like a software bug. But I would imaging that the install base is large enough that if there was a bug it would have been discovered by now. In this test case I'm taking advantage of the EVSE controller default mode which charges at minimum when the WiFi/TFT isn't connected. 

Interestingly, if I don't perform the test continuity on the pilot signal wire the procedure doesn't work. That makes me thing that maybe there is something wrong with the physical connection. When I'm in there probing with my multi-meter I wonder if I am moving the pin on the end of the signal wire inside the handle around enough to make a connection with the car when plugged in. There is a bit of play of that pin inside the handle. I have just tried mimicking the motions I go through when I check for continuity without doing the rest of the procedure and that doesn't seem to work.