Have you turned it off at the mains inside the house to reset it? Also worth doing the trip reset on the rolec itself. Then try the Leaf on another AC charger and see if it does the same to rule out the Leaf.

 

yes tried all that

 

To rule out a possible problem with the car (very unlikely given that it's a Rolec we're talking about) it really needs testing with a vehicle simulator box. That would show for sure if it's a charge point or vehicle fault, but in all probability it's an EPC failure in the charge point, and you may be better off just getting a replacement. There is the option of changing the Rolec EPC for the very much better Viridian one, which would also bring the charge point up to current safety standards. Not exactly a drop-in replacement, as the LED needs to be changed as well, but other than that it should be pretty easy to do.

 

Your Rolec probably predates the latest regs, as did mine, installed 2015. I updated it myself with newer EPC with all the latest safety bells & whistles. Mine lives in gge, if yours is outdoors you may want to glue a small acrylic window where the LED unit sits, as the Rolec LED unit is incompatible with the Viridian one, assuming you want to see the different colours/flashing etc the Viridian does on its built-in LED. Details here:
Rolec Dumb Charger upgraded with DC Leakage Protection...

 

Thanks everyone, I think I will have to seek out help to do any of the suggestions above. I don't want to make things worse.

 

It sounds like the communication unit is at fault.
It's about £100 and an hour or less to replace one and can be done DIY if your competent and safe!

The contactor can be replace on its own but as it's being instructed to open and close I would say that's not the issue.

 

It's about £100 and an hour or less to replace one and can be done DIY if your competent and safe!

Is it a direct like for like swap ?

 

Do make sure you tighten the screws properly tight! Ideally you'ld use a torque screwdriver set to the value given on datasheet for the module being wired up, but these things aren't cheap! I bought one of these:
DRAPER 9 Piece Torque VDE PZ/PH/SL Interchangeable Blade Screwdriver Set, 65372 4005069152338 | eBay
but may be available 2nd hand, or there's this which has enough range, but never used one myself:
Sealey 1/4"Hex Drive Digital Torque Screwdriver - Range 0.05-5Nm - Length 155mm 5051747908369 | eBay

 

Hi, you have mentioned tightening the screws whilst others have said use a torque screwdriver. If I don’t have a torque screwdriver will trust tightening the screws hard do the job? If they are not tight enough or too tight, what are the possible issues encountered. Thanks

 

It's now mandatory, not optional, to torque terminals to the manufacturer's stated torque setting for things like RCDs, RCBOs main switches, MCBs, isolator switches etc. Gradually manufacturers are now adding the terminal torque setting to device labelling, to save having to look it up. Long overdue, IMHO, as far and away the majority of overheating issues relate to poorly tightened or made off terminations. The exception is probably Rolec RCBOs, that seem quite capable of overheating even when the terminals are properly made off and torqued down. Just crap Chinese made stuff that's not been through proper testing or quality control I suspect.

 

When you gently unscrew each screw for the casing my advice is a dab of grease on each one before it goes back in, a silicone grease or even graphite if you wanted as it aropa the screws welding to the plastic in the heat extremes we suffer in this country and helps keep water ourand this reduce corrosion and likely break in the future as when they corrode in there the extra material locks okto the plastic even more.

 

UPDATE - I eventualy changed the Rolec controller for a Viridian and it seems to have sorted the issue. No more clunk clunk clunk.

thanks everyone

 

Hi. Was it an easy replacement? The labelling on the Viridian and Rolec are different so how did you determine which wire goes where? Thanks

 

There are other threads on this and one may have pictures if I remember correctly.

 

Rolec Dumb Charger upgraded with DC Leakage Protection...

I saw a very alarming video on here recently where an old, dumb Rolec EVSE was shown continuing to charge a car, even with the Earth wire pulled out & floating in mid air!!! I've also seen a reference elsewhere to an un-named, but commonly seen in domestic situations EVSE that failed to do any...

www.speakev.com

 

Yup. The amount of tightening required is surprisingly large in my limited experience. And the paper data-sheet for the particular RCBO/whatever will have the correct figure in, or you can probably google for it. I seem to remember the Garo RCBO had a higher tightening torque than many other makes, which themselves are pretty high torques anyway!

Draper make a nice adjustable torque screwdriver. Don't risk a burnt-out EVSE component & failed charge just because you didn't have the right equipment.