[lamrith]

My CO flex has never done that. Once it goes to low/off it never reconnects to the car. Wonder if it is a setting.

I have never had issue with it not starting to charge. I Normally pull in and leave the car on and plug in then turn the key off. To limit contactor cycles. But even if I don't do that the car always kick the contactors on and charges with the flex. This is typical cycle for me, car stopped just after 7pm with 95%, never topped off. 5:40am is me going out and turning car on to preheat before heading to work.

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[lamrith]

Okay, so the contactor deactivation glitch happened after aftermarket ChargePoint use.

ChargePoint is the ONLY public charger with which I've had consistent problems: All 20+ of my friend's work ChargePoints always fail to charge at all, until I hit their reset button. The only exception is if a 500e unplugs right before I plug in.

I still want to see the OBD contactor history from @abenusa & @MDMTahiti & @witmannerik

My gut is telling me the issue we are having has to do with the car ramping down charge rate near end of charge when taking max current.

I wonder if the car ramps down so low the charger assumes it is done and shuts off? Or does the car throttle back from thermals during charge? I am usually ~50% soc when start. Might need to try it from 60 or 65% to see if it goes to 100%?

I set mine to lowest amps I could and it always charged to 100%. So imho it is def related to charge rate. 5-6% is not issue for me so I leave it at max. Sometimes we need to run errands after home, so having it getting full 6kw for an hour is really nice insurance if need more range later.

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[fiatatat]

I had a contactor glitch today. Cleared the errors, no bueno. Then connected a 120V EVSE, and here goes the clunk. Needed to disconnect the 12V battery though to clear the dashboard light, though.

Wife then had the same, but I already showed her the trick with disconnecting the 12V battery (and I keep a 10 mil wrench in the car, as ETS once suggested). Disconnect, reconnect and clunk again.

It was a cold night and the car was sitting outside, when usually we keep it in the garage. Maybe something after a prolonged cold loses the ability to work?

 

[fiatatat]

Anyway, spoke too soon. Next morning, same story. This time the same procedure does not work.
The sound the contactor is making is now different, like the second half of it is gone.

Any ideas? Tried enabling the HV contactors through AlfaOBD, no luck yet.

 

[Electric Tire Shredder]

I'd run through the list of tricks in the link at the bottom of this post*.

Please confirm that the humidity sensor has been left unplugged, & you have the paid version of AlfaOBD, which we now know is required for contactor reset.

Please tell us if you know what errors you cleared. That might show in OBD logs, but keep in mind that the latest data is appended to the BOTTOM of the log. Click to enlarge how to find the file with the phone plugged into a computer:

Please tell us what dashboard light wouldn't clear until the 12V disconnect, & confirm that you know how tell if the the car was asleep before disconnecting.

Please confirm 11.6 volts or more in the system (either on OBD, or at the clamps, not the posts, in case there's a bad connection).

My next steps would likely be a longer 12V disconnect. I now recommend an 8mm x 1.25 wingnut, since it can't be lost like a wrench:

I'd combine it with an HV disconnect, paying close attention to the last 3 pics:

I can't recall any report of 3 hour disconnect worked when 5 minutes didn't. So I might just go for the full 30+ hours. Then if it still didn't work I'd try code clearing again, & if that didn't work, try the contactor reset again:

*

HOW TO FIX A "DEAD" 500E that suddenly...

Updated 2/27/23 If you’re stranded, it sometimes works to turn off the headlights, wipers, & dome lights, leave the hatch closed & the left door latched only 1 click (to avoid “wake-up” signal), wait about 15 minutes for the starter battery to rest, & try again. If it starts but just won't...

www.fiat500owners.com