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EVSE Plug/Cable Replacement Instructions
NOTE: Completing this procedure will almost certainly void your EVSE warranty!
Tools Required:-
No 2 posidrive screwdriver
4mm Flat screwdriver (ideally electrician’s)
2mm Flat Screwdriver
Mains tester
(Possibly) 8” Adjustable spanner
1/ ISOLATE THE EVSE (charge point box) from the mains supply. Do so by switching off the mains at the relevant consumer unit (‘fuse box’). Most EVSE supplies are wired via a separate isolation switch (NOTE: This is NOT the same as an MCB or RCD or RCBO but if the relevant device is a 2 pole one then this, when ‘Off’, will effectively isolate the EVSE). If it is isolated, none of the status lights will be illuminated on the front panel.
2/ Confirm isolation from the mains by using a mains tester to MAKE SURE none of the wires to the EVSE are live (this may not be possible without first removing the EVSE front panel).
3/ Use a No 2 posidrive screwdriver to remove ALL the self-tapping screws (usually about 4) from the edge of the EVSE front panel.
4/ Remove the front panel.
5/ The inside of the EVSE looks like this...
6/ TAKE A PHOTO of the inside of the box to allow you to check your (completed) re-wiring is correct.
7/ Slacken the gland nut on the ‘Car Plug Cable Out’ gland (the one on the outside of the EVSE box)...
8/ a/ Slacken the 'Live', ‘Neutral’ and ‘Earth’ terminals (as marked in red in the photo above) and pull the wires out.
c/ NOTE THE POSITION OF and then slacken the ‘CP’ wire terminal and pull out the CP wire.
9/ Remove the transient suppressor block (the white rectangular device beneath the red ‘EARTH’ label in the photo. It may be necessary to either separate the 2 halves of the suppressor block to do this, or to cut off the ferrule.
10/ Un-do and remove the translucent cable clamp (just below the transient suppressor block in the photo).
11/ Gently pull the ‘Car Plug Cable Out’ cable ends out through the cable gland.
12/ Gently insert the ends of the new ‘Car Plug Cable Out’ cable. Staggering the ferruled ends of the conductors may make this easier rather than trying to do them all at once.
13/ Connect the wires:- Live, Neutral and Earth wires to their respective terminals. All these 3 connections should be as tight as you can get them without allowing the screwdriver to slip on the screw-head. Connect the ‘CP’ wire to its terminal. The new CP wire may be a different colour to the original but it will be clearly marked ‘CP’. It is ESSENTIAL that ALL these are correct. If you mix them up you could not only damage your EVSE...
***BUT ALSO YOUR ELECTRIC VEHICLE'S CHARGER***!
14/ Tighten the ‘Car Plug Cable Out’ gland nut such that the ‘Car Plug Cable Out’ cable cannot be pulled out using reasonable hand force. The spanner may be required.
15/ Locate and re-attach the cable clamp.
16/ Replace the EVSE front panel. Make sure the lips and screw holes from front an back halves of the box are properly aligned before firmly pushing the lid home. It is a bit fiddly so make sure the lid is properly in place before inserting and tightening the screws. Do not over-tighten the screws.
17/ Switch on the mains.
I strongly advise that after a week or so of heavy use (ie 10kWh or more of charging per day) the front cover of the EVSE be removed and the Live and Neutral connections be checked for any signs of overheating (‘sweating’ of the plastic insulation, browning or (hopefully not) charring or obvious ‘burning plastic’ smell. If any sign of this is found, check the terminal is TIGHT! Then check again after a similar period of use. If heating is still found, consider replacing the affected component and/or re-doing the connection.
NOTE: For liability reasons, I strongly urge you to undertake what follows ONLY if you are ‘suitably qualified’. If you do something silly, you could very easily DIE!!!
Contact Us...
Email: sales@EVBitz.uk - Mob: 07788 138413
2 Hall Cottage
Isle of Colonsay
Argyll
PA61 7YT
Scotland
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