Charging: Stopped by System Malfunction

[Improve_RAV4EV]

Gentlemen,
60.4Ω resistor is soldered betw pins 3 & 9 on X042 (can you tell? It's all black (shrink tubing)).
Time to put OBC and the rest back on car and test it.
I'll be back with the result.

 

[alflash]

... 2. Can you formulate in one sentence of no more than 10 words the main purpose of the entire HVIL line fragment that is in the Charger?

Gentlemen,
60.4Ω resistor is soldered betw pins 3 & 9 on X042 (can you tell? It's all black (shrink tubing)).
Time to put OBC and the rest back on car and test it.
I'll be back with the result with the preservation of the functions of the system

There is a beautiful and correct solution \ with the preservation of the functions of the system
https://alflash.com.ua/2019/to_rav4ev/ch_hvil.jpg

 

[davewill]

Questions for the participants.
1. Can you formulate in one sentence of no more than 10 words the main purpose of the entire HVIL line?
2. Can you formulate in one sentence of no more than 10 words the main purpose of the entire HVIL line fragment that is in the Charger?

To verify that no high voltages are open to touch.

Ten by the rule.

 

[Improve_RAV4EV]

There is a more beautiful and correct solution
https://alflash.com.ua/2019/to_rav4ev/ch_hvil.jpg

Thanx, but little bit too late. Next time.

Is the Reed Switch actually a diode?
What are the specs of this component, please?

 

[alflash]

To verify that no high voltages are open to touch.

Ten by the rule.

Yes, I agree. And in the charger, this is done by a jumper
https://alflash.com.ua/2019/to_rav4ev/charger_jumper.jpg

and a reed switch, which perform the function. They and a 60 Ohm resistor must be "in action" to comply with the current mode.
Although, as I understand it, the jumper in the RAV4EV charger is useless.

Thanx, but little bit too late. Next time.

Is the Reed Switch actually a diode?
What are the specs of this component, please?

A reed switch is a sealed contact pair that closes under the influence of a magnetic field. Removing the charger cover removes the magnet and the reed switch opens, and the HVIL circuit is open.

With this repair method, this resistor should have been placed on the back of the male D4 connector

 

[alflash]

Probably in case somebody opens the OBC lid while driving

p.s. As Tesla teaches, "opening the lid while driving", that is, opening the HVIL line while the car is moving, will not cause the contactors to open.

 

[Improve_RAV4EV]

p.s. As Tesla teaches, "opening the lid while driving", that is, opening the HVIL line while the car is moving, will not cause the contactors to open.

I meant the HV electrocution, if he opens the lid and touches HV.

 

[asavage]

However, all the checks are made with lid & side frame off. In other words, J5 was out !
Should I repeat the tests with the frame and J5 inserted?

Without the external jumper J5, you'll never get a reading at X042 (D4) 3 & 9. It's a required loopback to complete the HVIL circuit.

Matt mentioned this in post #9, "For now you can just do the black low voltage connector on the OBC driver's side, and skip the AC and HV connections until later (but do make sure the white jumper connection at that end of the charger is still installed)."

Matt again in post #69, " . . . there should be a little jumper plugged into the white three pin connector (refer to middle picture of post #43 above). It's pretty easy to knock this jumper out while moving things around."

[A non-sequitur here, but for future readers: the external jumper J5's purpose is to allow interfacing with the Rear HVJB's Lid Switch in a Tesla Model S/X. It's also used when an optional Dual Charger configuration was purchased for those models, as the second OBC doesn't interface with the Rear HVJB. Since there is no Rear HVJB in the RAV4 EV, there's a jumper installed -- always.]

 

[asavage]

Gentlemen,
60.4Ω resistor is soldered betw pins 3 & 9 on X042 (can you tell? It's all black (shrink tubing)).

Unsubscribed.

 

[Improve_RAV4EV]

Without the external jumper J5, you'll never get a reading at X042 (D4) 3 & 9. It's a required loopback to complete the HVIL circuit.

If you remember, before removing the OBC (J5 was in place), I made a little harness and connected it to pins 3 & 9 of X042 to read the Ohms. It showed OL.

 

[Improve_RAV4EV]

I put the OBC in the car and connected all the cables, including HV & AC.

Connected my little harness to X042 and checked pins 3 & 9. It first jumped around, then showed 67 Ohms.
I did another measurement, this time it stabilized at 72 Ohms.