I believe there's a thermal sensor in the 3-pin plug to ensure that your plug/socket doesn't overheat due to any loose terminals or or unknown unpredictables.
Deborah.

 

There have been a few threads on this topic over the years. As @High & Dry says the original plug has a thermister wired to the two extra leads that reduces power if the plug overheats. This is one typical thread.

Putting a new plug on an EVSE - and the thermal sensor...

In case you ever have the need to put a new 3 pin domestic plug on your EVSE here is what I did. Obviously you 'poke and play' at your own risk. I should say that I used a heavy duty rubber plug and16A rated cable. The reason I needed to do this was that I had acquired a brick with a...

www.speakev.com

 

Do you know if there is any way of successfully wiring it into a standard 3 pin plug?

 

Yes. But outside my pay grade. Seems to involve inserting a resister, replacing the original equipment, or making amendments inside the EVSE itself. As I said, many threads over the years. The forum search function is your friend.

 

you might be able to pare away the plastic on the original plug and extract the thermistor. Alternatively, someone might have posted the value somewhere. The linked thread mentions a 22k NTC thermistor, but i dont know if thats the same charger as you have.

If you have a meter, you can very likely take some readings from your existing sensor at a few different temperatures to figure out what it is.

 

It should of course be pointed out that replacing the thermistor with a suitable fixed value resistor is just a way to "fool" the EVSE into thinking the plug is not overheating when it might actually be. In other words this safety feature is being defeated by doing so. If this plug later catches fire or melts then you might well regret this.

To be honest cutting the plug off was a mistake and you're in a bit of a mess now.

It's not easy to repair this in a properly satisfatory way, certainly not with a regular screw terminal plug as even if you used an appropriate thermistor to maintain temperature sensing there isn't an easy way in such a hollow plug to provide thermal bonding between a thermistor and the parts that get hot (mainly the fuse holder and phase pin) while at the same time maintaining adequate insulation between the high voltage and the sensor.

In a moulded plug like the original there are no hollow voids apart from the fuse holder space, with any other spare space filled in with plastic which acts as both electrical insulation and a (partial) thermal conductor between the heat source and the thermistor allowing it to sense when the plug is heating up.

If you use a screw terminal plug you're going to have to bodge it with a resistor and lose temperature sensing, and its probably infeasible to rejoin the cable depending on where you cut it. (Unless you cut it close to the EVSE end and have enough length to reterminate it inside, but I'm guessing you probably cut it close to the plug)

The only 100% professional repair would be to try to get hold of a faulty EVSE of the same model and steal the cable from it, reterminating it inside, getting you back to where you started.

And then change your socket to one with a bigger cover so that the original plug size fits...

 

Thanks all

DBM - you mentioned that there is a socket with a bigger cover - is this one made by Rolec? If you have any details id appreciate thatbotherwisw I assume I’ll,find it in a search. I just don’t remember it being an option.

Jak

 

I use one of these

EV granny charger 13A weatherproof extension lead

High quality 13A weatherproof outdoor waterproof extension leads heavy duty 1.5mm H07RN-F rubber cable. RCD option. IP66. Designed specifically to overcome the issue created by chunkier plugs on electric vehicles (EVs). 2m, 5m, 10m, 15m, 20m and 25m lengths.

www.toughleads.co.uk

 

>>Do you know if there is any way of successfully wiring it into a standard 3 pin plug?<<<<

There is a post on here somewhere where someone had one of these rewired( I believe it was connected to HANDYANDY it either belonged to him or he mended it)
I hope I am right and this was not another webdite

 

I saw one for sale on eBay not so long ago, the seller said the 3 pin plug had been removed and re-wired with a commando plug.

If your going to fudge a resistor, it may be a safer option than an 3 pin domestic?

 

BG WP23L Single Outdoor Weatherproof Socket Large | ElectricCounter

The BG Nexus Storm WP23L Outdoor Weatherproof Socket is perfect for outdoor uses needing larger plugs. Shop Weatherproof Switches and Sockets now at electricalcounter

www.electricalcounter.co.uk

 

I would consider a pro job and put it all down to experience. £90 for a repair inc return postage. Then find a larger socket housing.

Cable Repair Service

 

>>>Delphi Granny Charger Repair IC-CPD Aptiv 240V 10A<<
This is the discussion about the chopped cable

 

Thanks - I do doubt my ability - is this a job for any electrician or am I looking for a specialist? Thanks

 

Any half decent spark with a soldering iron, the resistor and some heat shrink would be able to do it.
Let's face it, I managed. 😂

 

Thanks - I’ve managed to dig out the moulded plug and have the part I need (pic below). There isnt any room inside a standard plug for it - or at least not with safe separation from the other 3 terminals. However, does It need to be inside the plug? Is it actually measuring in some way the temperature of the plug or can it be installed inline but not inside the plug?

Thoughts welcomed.

 

You will easily fit that in a standard plugtop. Just put some heatshrink over it.
A MK Duraplug will accommodate it, promise.

 

Keep an eye on eBay for a Nissan EVSE with a type 1 terminal, last one I saw went for £80.

I think it will be cheaper and safer in the long run, keep yours as a spare in case it goes wrong.

 

It needs to go inside the plug. Its measuring the temperature of the plug to ensure it doesnt overheat (due to poor connection in an old/worn out socket for instance)

I'm sure you can squeeze it in, sleeve it in some heatshrink tubing to protect it

 

If it's just sitting loose inside it won't actually protect against overheating though since it won't have sufficient thermal transfer from the bits that get hot.