Complete diagnostic testing of the high-voltage charging system, onboard charger, charge port, and DC fast charging capability on the 2024 Rivian EDV 500 electric delivery van.

Warnings

Tools required

Preparation

1. Ensure vehicle is parked on level ground in a well-ventilated area with adequate lighting
2. Verify 12V auxiliary battery is fully charged (charging system tests drain auxiliary battery)
3. Ensure vehicle state of charge is between 20-80% for accurate testing
4. Confirm no active fault codes preventing charge system operation
5. Download latest Rivian diagnostic software version and any pending vehicle software updates
6. Inspect charge port door for physical damage, debris, or moisture intrusion
7. Have vehicle VIN and service history available for diagnostic software authentication

Procedure

1. 1

   Connect diagnostic equipment and perform initial scan
   Connect the Rivian diagnostic interface to the vehicle's OBD-II port located under the driver side dashboard. Launch diagnostic software and authenticate with vehicle VIN. Perform a complete system scan and document all existing fault codes in the Battery Management System (BMS), Onboard Charger Module (OCM), and Charge Control Module. Check for any active interlocks or charging inhibit flags. Review charge history data including last successful charge, any interrupted charge sessions, and charge power limitations.
2. 2

   Verify 12V auxiliary system operation
   Test the 12V auxiliary battery voltage with vehicle off (should be 12.4-12.8V). Measure voltage with vehicle in accessory mode (should maintain above 12.0V). The auxiliary battery powers the high-voltage contactor control circuits and charging system logic. Verify the DC-DC converter is functioning by checking 12V system voltage with vehicle ready (should be 13.8-14.4V). Test auxiliary battery load capacity as weak auxiliary battery is a common cause of charging failures.
3. 3

   Inspect charge port hardware and connections
   Open the charge port door and visually inspect the J1772/CCS1 combo receptacle for pin damage, corrosion, debris, or discoloration indicating overheating. Check that all contact pins move freely and spring back to position. Inspect the proximity detection pin and pilot signal pins specifically. Look for any moisture, insect nests, or foreign objects. Check the charge port door actuator operates smoothly and the charge port LED illuminates when door opens. Inspect the charge port lock mechanism for proper engagement.
4. 4

   Test charge port communication circuits
   Using the diagnostic software, command the charge port lock to engage and disengage, verifying mechanical operation and electronic feedback. Test the proximity detection circuit by measuring resistance between proximity pin and ground with no cable connected (should read open circuit). Check pilot signal circuit voltage with no cable connected (should read 12V or floating). Verify charge port temperature sensor reading is within ambient temperature range. Test the charge port LED circuit by commanding different LED states (white, green, blue, red) through diagnostic software.
5. 5

   Perform Level 2 AC charging system test
   Connect a known-good J1772 Level 2 charging cable (or instrumented test plug) to the vehicle charge port. Using diagnostic software, monitor the pilot signal duty cycle (should transition from 12V to 9V when cable detected, then PWM signal indicating available current). Command charging to begin and verify the onboard charger activates. Monitor AC input voltage and current on all three phases if using three-phase charging, or L1/L2 voltage and current for split-phase. Verify charging power ramps up to expected level based on EVSE capacity and vehicle acceptance rate. The EDV 500 should accept up to 11.5kW on AC charging. Monitor onboard charger inlet and outlet coolant temperatures during charging.
6. 6

   Monitor AC charging performance and thermal management
   Allow AC charging to continue for at least 15 minutes while monitoring via diagnostic software. Check that battery pack current, voltage, and power values match expected parameters. Verify the Battery Thermal Management System (BTMS) activates if needed to maintain optimal charging temperature (15-35°C battery pack temperature). Monitor onboard charger component temperatures including IGBT modules, inductor, and capacitor bank temperatures. Check cooling pump and fan operation if equipped. Use infrared thermometer to scan charge port pins for hot spots indicating high resistance connections. Verify no power derating or current limiting occurs during sustained charging.
7. 7

   Test DC fast charging system communication
   Disconnect the AC charging cable and allow 2 minutes for system reset. If available, connect a CCS1 DC fast charging cable (or test adapter with communication capability). The vehicle must complete ISO 15118 or DIN 70121 communication handshake with the charging station. Using diagnostic software, monitor the communication sequence including vehicle identification, charge parameter exchange, isolation test, and precharge sequence. Verify the vehicle correctly reports battery capacity, state of charge, charging curve limits, and maximum charge current (EDV 500 supports up to 150kW DC fast charging). Check that high-voltage contactors close on command during precharge.
8. 8

   Verify DC fast charging operation and power delivery
   If connected to a functional DC fast charger, initiate a charging session and monitor the charging curve through diagnostic software. Verify the vehicle accepts DC current at appropriate levels based on state of charge (highest power at low SOC, tapering at higher SOC). Monitor battery pack voltage, current, and individual module voltages for imbalance. Check that charging power reaches expected levels (up to 150kW depending on battery temperature and SOC). Verify DC contactors remain closed and no interruptions occur. Monitor insulation resistance continuously during DC charging (should remain above 100 ohms/volt). If no DC fast charger available, use diagnostic software to perform DC charging system self-test and contactor operation verification.
9. 9

   Test high-voltage isolation and insulation resistance
   After completing charging tests and disconnecting all charging cables, place vehicle in service mode through diagnostic software. Disable high-voltage system and verify contactors are open. Wait 5 minutes for HV capacitor discharge. Using the megohmmeter, perform insulation resistance testing between HV positive bus and chassis ground, then HV negative bus and chassis ground. Minimum acceptable insulation resistance is 500 ohms per volt of pack voltage (typically 100+ megohms for EDV 500 system). Test with vehicle high-voltage system de-energized. Low insulation resistance indicates potential ground fault in battery pack, cabling, or charging system components.
10. 10

    Verify onboard charger component integrity
    With high-voltage system disabled, perform visual inspection of the onboard charger module located in the front vehicle compartment. Check all HV and AC connections are tight and show no signs of arcing or overheating. Verify coolant connections to onboard charger have no leaks (if liquid-cooled). Check cooling fans operate when commanded through diagnostic software. Inspect HV cable routing and orange conduit for any damage or chafing. Verify all HV interlocks are properly seated and functioning by monitoring interlock status in diagnostic software while gently moving connectors.
11. 11

    Test charge scheduling and smart charging features
    Through the diagnostic software or vehicle interface, verify charge scheduling functions operate correctly. Set a departure time and verify the vehicle calculates appropriate charge start time. Test charge current limiting feature by setting maximum charge current to a reduced value and verifying it is respected during a test charge. Check that location-based charging preferences function if configured. Verify vehicle correctly responds to grid signal inputs if equipped with vehicle-to-grid or demand response capability. Test any fleet management charging features specific to EDV commercial configuration.
12. 12

    Analyze charge system data and compare to specifications
    Review all captured data from charging tests. Compare AC charging power acceptance to specified 11.5kW maximum. Verify DC fast charging followed proper charging curve for battery state of charge and temperature. Check that no thermal limiting occurred at normal ambient temperature. Review any efficiency calculations between AC input power and DC battery charging power (should be 92-96% efficient). Verify charging session was logged correctly in vehicle system with accurate kWh metering. Check for any anomalies in voltage, current, or temperature trends during charging.
13. 13

    Perform final system verification and clear adaptive values
    Clear any diagnostic trouble codes that were resolved during testing. Reset charging system adaptive values if available in diagnostic software to clear any learned limitations from previous faults. Perform a final complete system scan to verify no new faults were introduced during testing. Verify all charging system interlocks show closed/ready status. Test one final brief charge cycle (2-3 minutes) with AC charging to confirm system operates normally. Document all test results including charge power achieved, any derating observed, component temperatures recorded, and insulation resistance measurements.

Reassembly

1. Disconnect all diagnostic equipment and test cables from vehicle
2. Close charge port door and verify it latches securely
3. Return vehicle to customer mode from service mode in diagnostic software
4. Verify charge port lock operates from vehicle interface or key fob
5. Clean any fingerprints or debris from charge port area

Verification

• Perform a complete charge cycle from current SOC to 100% using customer's normal charging equipment to verify real-world operation
• Verify no charging fault codes are present after test completion
• Confirm charge port LED displays correct status (white when ready, green when charging)
• Check that scheduled charging functions as configured
• Verify charging session data is correctly logged in vehicle system and available through owner app
• Confirm charge power acceptance meets specifications: 11.5kW AC Level 2, up to 150kW DC fast charging
• Document all test results and provide charging system health report

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