Wall Charger Arcing / Melting?

[AMaier]

My gen 1 R1T has been failing to charge recently (usually due to it falling asleep mid charge, but sometimes due to "vehicle error"). One of the pins in my Rivian Wall Charger has rapidly turned black (I checked it the other day and it was fine then), and the matching pin on the vehicle has some pitting or something on it. I pretty much only charge with Rivian brand equipment at home, and rearly use a 'supercharger'. The side of the charger that looks to have arced runs noticeable hotter than the other half of the charger.

Questions:
• Does this mean a full replacement of the EVSE and vehical wiring harness?
• Is this typically a warranty item?
• If you have been through this before, what was your experience (photos welcome for reference).

Precautions:
• Stopped charging with that EVSE (we have two)
• Charging vehicle outside instead of in garage
• Might try to wipe out the charger with rubbing alcohol and let it sit for a while

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[captainjp]

The vehicle pin looks more like it has melted plastic from the plug rather than pitting.

That should be cleaned out before plugging-in again.

 

[Dave Cundiff]

I'd start with (855) RIVIAN-5, @AMaier. Might need to open a ticket and upload photos as well.

Another option, if you had no other available charger, might be to limit the amperage. Better not to use it at all, though, until this is clarified. Arcing is likely independent of amperage.

Best wishes!

 

[Time2Roll]

I would stop using that EVSE. Have the vehicle inspected. Yes ask about warranty coverage.

I recommend replacement over any cleanup. Will never be like new and always more prone to issues.

 

[WhidbeyIsland]

Let us know how it goes with Rivian and their willingness to replace/repair the charger.

 

[sac602]

Also, turn off breaker and tighten all the wires in the breaker box and going into charger. Mine loosened up. Electrician said the large spike in voltage causes expansiin/contraction and can case wires to loosen. Mine would error (no Arcing) but tightening fixed the issue.

 

[AMaier]

Here are a few more photos.

Rivian support (phone) were able to get me a new wall charger under warranty, and an electrician to do the replacement free of charge (unless they find code violations or need to pull a permit, resolving those things may be required and extra). They did ask for proof of purchase and if the electrical was installed by a professional and with a permit, etc. Lots of pictures too, including inside the breaker panel and inside the EVSE unit, as well as wide angle photos of the install location (probably to validate it is a real and proper install and not internet photos or a poorly rigged unit).

The phone support rep also said that despite my 60amp circuit, I should flip the dips in the new charger to a step below max current because my Romex (sleeved) wire can't dissipate heat well enough and could cause a fire (unrelated to the issue I had). It was a professional install, so I'll just call the electrician back and see what they say and if they will swap the wire out.

The Rivian Service Center is separately replacing the charge port and wiring harness in the vehicle under warranty. About a week of work. They made it clear that I can not charge with the old unit after the repair as that could cause the issue to occur again (due to the degraded contacts).

Overall Rivian has done great with this issue, although neither of the departments could handle everything, and I had to share information between them to get it done and confirm what the other was doing (such as confirming to the service center that the phone support reps were getting the EVSE replaced, so I could charge at home again and wouldn't mess up the car.) They wanted it done in lockstep but didn't communicate directly with eachother. Fine for me, but the process could fall down for others.

The only other down side is that the QMerit installer Rivian provided sent me a poorly written email, which makes me a bit concerned about quality and detail of the installation. That said, assuming English isn't their first language, I should probably give them the benefit of the doubt and see how well they do. I'm just having them do it so Rivian is happy to help again if anything goes wrong. (The install is literally just hanging the unit, tightening the lugs, and flipping the dips).

 

[electruck]

If your electrician wired up an EVSE with 6 awg Romex on a 60 amp circuit, you need to find a qualified electrician that is actually familiar with EVSE installs. That is absolutely not up to code for 48A charging.

 

[AMaier]

I called back the original electrical install company (a large local company that does both residential and commercial work) and they tried to say it was fine because it isn't continuous use (which is incorrect). I told them an EVSE is always continuous use per code and, besides that, they installed under-rated wire for the breaker that they also installed. I told them they needed to come replace it at their expense since it is their work that could burn my house down. They came out, inspected it, blamed the original electrician who 'doesn't work with them anymore' and swapped it out for 6AWG THHN in conduit. They also installed the new EVSE, so I don't need to deal with QMerit anymore.

 

[Time2Roll]

Was the NM-B in the wall? I think I would have moved it to 40A before dropping that conduit.

Glad to hear all is working and made right under the warranty.

I self installed mine yesterday. I assume any warranty could be a bit of a fight.

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