Difficulty
Easy
Steps
7
Time Required
00:30:00
- Relay Maintenance 7 steps
User-Contributed Guide
This guide is not managed by the site's staff.
Introduction
Troubleshooting and repairing a "Stuck Relay" error.
This repair procedure applies to any OpenEVSE with an open-air relay (contactor) such as the 50A - Struthers - Dunn.
If your relay is a sealed unit, replace the entire relay.
Parts
No parts specified.
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EV standards (IEC and SAE) require charging stations to provide soft start and soft stop of each charging session.
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A properly functioning station should never require relay maintenance.
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Ensure that the button on SAE J1772 plugs and lock/unlock are functioning properly to automatically remove all load before disconnecting vehicle.
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The plug should never be disconnected under load if the button/unlock are working correctly.
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Turn power off to your OpenEVSE unit at the breaker
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Validate that your OpenEVSE unit is off
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Open your OpenEVSE unit
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Validate that voltage is not present with your multimeter to ensure electricity is off
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Inspect the relay, ensure the contacts open and close as expected.
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Gently tug any stuck contacts to free them.
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If the relay is seriously damaged, melted, bent, broken, or the contacts cannot be separated, replace it.
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If relay is lightly pitted, or has other debris or build-up as shown in picture, continue guide to clean.
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'Ensure any sharp metal burrs are removed from the edges of contacts. A metal file might be required.
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Cut a piece of coarse emery cloth roughly 3x the width of the contact (normal sandpaper is not recommended as it can leave deposits of other metal types on the contact surface)
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Fold the piece of coarse emery cloth, and place it between one set of contacts at a time. Apply gentle pressure to the contacts and sand evenly between the two surfaces.
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Repeat process above using coarse, medium, and fine emery cloth to ensure a good connection.
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Close the relay by gently pressing the plastic top bracket. Ensure an even and flat connection between the contacts.
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Once your contacts are evenly sanded, use contact cleaner and a q-tip to scrub each contact surface removing any build-up, metal, or grease
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Reassemble your OpenEVSE and power it on.
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Monitor the self-test to ensure errors have cleared
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Attach a vehicle and charge at the full rate, monitor the OpenEVSE unit for any excessive heat build-up.
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If any excessive heat is detected on the OpenEVSE unit, replace the relay.
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Slowly plug and unplug the vehicle a few times ensuring the relay opens and closes as expected each time.
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