This one beat me up pretty bad before I figured it out:
In the wire harness that connects the EVSE charge port to the PCU there are crimped barrel splices. I found one of these splices to be an intermittently open circuit.
This will be an additional mandatory retrofit to every Think that comes in with a no-charge condition. So in addition to removing the FU2 and FU3 (replacing with jumper wires) and installing inline fuse holders in the EVSE wire harness, I will also be removing the crimped splices and replacing them with a solder splice. It might not be a bad idea to do this as a preventative service, too.
I believe that the Thinks were shipped from Finland to Indiana with an EVSE connector that is different than the J-1772 standard that we use in the US. And thus, I suspect the connectors were loped off and new ones installed. The protective orange loom that encloses the EVSE wires changes from one shade of orange to another shade about 1 foot from the EVSE port, behind the left front fender, and the joint is covered by black heat shrink. The crimped splices are in this same area, so the left front fender must be removed to access them.
I would like to know exactly what signals the various wires carry. The larger wires (black, blue and green/yellow) are obviously for main line voltage, neutral, and ground. I put an oscilloscope on the other smaller two wires while I had a vehicle charging, and it seemed that one was just ground with some noise and the other looked like a pulse width modulated signal at 1 kHz. With a level 1 Leviton EVSE it went from about 12% to about 22% after I pressed the button on the EVSE to raise the charge rate to 12 Amps. Can anyone out there please explain to me exactly what these wires do (or are supposed to do) according to the SAE standard?