This procedure tests the high-voltage charging system on the 2023 Rivian EDV 500 to verify proper operation of the onboard charger, charge port, and associated electrical components.

Warnings

Tools required

Preparation

1. Park vehicle on level surface in well-ventilated area with access to both AC Level 2 and DC fast charging if available
2. Verify battery state of charge is between 15-85% for optimal testing conditions
3. Allow battery pack to stabilize to ambient temperature (minimum 2 hours after driving)
4. Connect Rivian diagnostic software to vehicle OBD-II port and establish communication
5. Verify no pre-existing DTCs related to charging system; document any existing codes
6. Ensure shop electrical service can support full Level 2 charging current (minimum 48A recommended)
7. Confirm vehicle software is up to date; check for any charging-related TSBs or updates

Procedure

1. 1

   Perform initial system scan
   Using Rivian diagnostic software, perform a complete vehicle scan focusing on Battery Management System (BMS), Onboard Charger (OBC), and Vehicle Control Module (VCM). Document all DTCs, freeze frame data, and current battery parameters including voltage, temperature, and state of charge. Review charging history for any anomalies or fault events.
2. 2

   Inspect charge port assembly
   Open the charge port door and visually inspect the J1772/CCS1 combo port for physical damage, corrosion, debris, or signs of overheating. Check all pins for proper alignment and condition. Verify charge port door operation and locking mechanism function properly. Inspect charge port wiring harness and connectors for damage or looseness.
3. 3

   Test charge port lock mechanism
   Using diagnostic software, command the charge port lock to engage and disengage. Verify audible and tactile feedback of lock operation. Manually attempt to remove a connected (unpowered) charging cable while locked to confirm mechanical lock is functioning. Check charge port LED indicator patterns match expected behavior per service information.
4. 4

   Perform AC Level 2 charging test
   Connect a known-good Level 2 EVSE (minimum 32A capacity) to the vehicle charge port. Initiate charging through vehicle interface and verify charging begins within 10 seconds. Monitor diagnostic software for proper pilot signal detection (should show +12V, +9V, and +6V state transitions). Verify vehicle negotiates maximum available current based on EVSE capacity. Allow charging to proceed for minimum 15 minutes while monitoring.
5. 5

   Monitor AC charging parameters
   During AC charging, monitor the following parameters via diagnostic software: input voltage (should be 208-240V AC), input current (should match EVSE capacity within 5%), onboard charger DC output voltage (should match battery pack voltage ±5V), DC charging current, charger efficiency (typically 92-96%), and all temperature sensors including charger inlet, charger module, and battery inlet temperature. Document all readings.
6. 6

   Perform thermal imaging inspection
   While AC charging is active at full current, use infrared thermometer to check temperatures of charge port pins, charge port housing, onboard charger coolant lines, and HV cable connections accessible from underneath. All charge port pins should be within 10°F of each other. Any hot spots exceeding 140°F require investigation. Stop charging and allow cooldown before proceeding if excessive temperatures detected.
7. 7

   Test charging interruption and resume
   During active AC charging, interrupt charging using vehicle interface. Verify charging stops within 2 seconds and pilot signal transitions to standby (+12V). Resume charging and confirm charging restarts without faults. Disconnect EVSE while charging is active and verify vehicle safely terminates charging session and logs event appropriately. Reconnect and verify charging can restart normally.
8. 8

   Verify ground fault protection
   Access onboard charger ground fault monitoring data through diagnostic software. Verify ground fault detection thresholds are within specification (typically ±500Ω isolation resistance minimum). Review any logged ground fault events. If equipped with ground fault test function in diagnostic software, perform automated ground fault detection test and verify system responds appropriately.
9. 9

   Test DC fast charging capability
   If DC fast charging station is available, disconnect AC EVSE and connect CCS1 DC fast charger. Initiate DC charging session and verify vehicle establishes communication with charger within 30 seconds. Monitor handshake sequence through diagnostic software showing voltage/current negotiation. Verify DC charging begins and current ramps up appropriately based on battery temperature and state of charge. Allow DC charging for minimum 10 minutes.
10. 10

    Monitor DC charging parameters
    During DC fast charging, monitor DC input voltage (should be 50-400V depending on charger type), DC input current (verify matches negotiated rate), battery pack voltage, individual cell voltages for balance (maximum 0.050V spread between highest and lowest cells), battery inlet/outlet temperatures, and charging power (kW). Verify battery thermal management system activates if needed. Document peak charging rate achieved.
11. 11

    Test scheduled charging function
    Stop all charging and disconnect EVSE. Using vehicle interface or mobile app, configure a scheduled charging time for 10 minutes in the future. Connect Level 2 EVSE and verify vehicle does NOT begin charging immediately. Wait for scheduled time and confirm charging begins automatically. Test departure time-based scheduling if supported. Verify time-of-use rate settings affect charging behavior as expected.
12. 12

    Verify charge rate limiting functions
    Access vehicle charging settings and test charge current limiting features. Set maximum charge current to 50% of EVSE capacity and verify vehicle respects this limit during charging. Test location-based charge settings if configured. Verify battery charge level limit setting (e.g., charge to 80%) properly terminates charging at target SOC. Reset all settings to customer preferences.
13. 13

    Check cooling system operation
    Review battery and motor coolant system operation during charging tests. Verify coolant pump activation during charging, check for proper coolant flow rates through diagnostic data, and confirm coolant temperatures remain within normal range (typically 50-95°F during charging). Listen for abnormal pump noises. Check coolant level in reservoir if accessible and verify no leaks in cooling system.
14. 14

    Perform final system verification
    Disconnect all charging equipment. Perform final vehicle system scan and verify no new DTCs were generated during testing. Clear any test-related codes if appropriate. Review all logged charging events and confirm they match performed tests. Verify all charging system components show normal status. Document final battery state of charge, all test results, and any recommendations in repair order.

Reassembly

1. Ensure charge port door closes and latches properly
2. Verify all vehicle covers and underbody panels are reinstalled if removed during inspection
3. Confirm diagnostic equipment is disconnected and all vehicle systems are in normal operating mode
4. Reset any test configurations to customer's preferred settings including charge limits and scheduled charging

Verification

• Perform one complete AC Level 2 charge cycle from current SOC to customer's preferred charge limit and verify normal operation with no faults
• Verify charge port LED indicators display proper status throughout charging
• Confirm no DTCs present in any vehicle modules related to charging system
• Test charge scheduling, rate limiting, and other customer-configured features are working as expected
• Verify charging session data is properly logged in vehicle history and accessible through owner app
• Confirm battery thermal management operated appropriately during testing with coolant temperatures remaining in normal range
• Document actual charging rates achieved match vehicle specifications for both AC and DC charging based on battery conditions

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