The most common failure is not the connector, it's in the cable. The tiny pilot signal wire (by comparison to the much larger power wires) often gets broken from stress. This is more common with portable EVSEs, and where people wrap the cords without proper technique. NEVER WRAP CORDS OF ANY KIND OVER YOUR ARM! It puts torsion (twisting) on the cable and causes excessive knotting at first, then ultimately conductor failure.
If you watch any professional who handles cables, they will be using the proper method, called "over under" because it wraps the cable without twisting. Here is a short example video: https://www.youtube.com/watch?v=RE-z5UteKfc (This is for XLR audio cables, but the concept is the same for any cable, and even more important the larger the diameter!) On larger/longer cables, just make bigger loops. It takes some practice at first, but with a little repetition it will become muscle memory. This will also mean way less tangles. Sadly your cables that have been twisted will never fully recover, but if you start this on new cables, you will never have trouble. Just as the guy in the video shows, you can literally throw the cable and it will lay mostly flat with no loops and knots! DO NOT do the thing I see contractors do with the chain loop trick! This doesn't twist the cable, but it does create many tight loops that stress the cable because you are subjecting it to beyond the minimum bend radius! Listen to the roadies! Back to the whip replacement on the clipper creek: You can find decent high-quality cables on Ebay all the time, you just need to make sure it's long enough and rated for 32A minimum, as that's what the CS-40 needs (Don't be fooled by the "40", it's a 32A EVSE!) Here's an example for $80: https://www.ebay.com/itm/305691551650 Any electrician can install this, it's 1 ground wire, 2 power wires, and the small pilot wire. (you don't need any extra small wires, such as proximity) On Wed, Oct 9, 2024 at 7:46 AM Jay Summet via EV <ev@lists.evdl.org> wrote: > If it is a standard J1772 connector/cable, you can find replacement > parts (the J1772 gun with or without the cable) easily online. > > The trick is getting a "good quality" one (UL listed, known > manufacturer, etc...) which will cost significantly more than a > "generic" one. [WAG on the price of a "good" J1772 gun: $100-200] > > There are 3 larger power wires (Hot/Hot/Ground) and 2 smaller data > cables that need to be connected (either on the gun end, or if you also > replace the cable, at the CS-40 end. > > Replacing the gun at the end of the existing cable would probably be > easier than replacing the cable inside the clipper creek unit, depending > upon how easy it is to open up the CS-40 unit. > > Although the replacement isn't difficult, a "regular" electrician may > not have done it before, so if you can find somebody who specializes in > EVSE installations that may help. [Even so, they typically install > entire units, instead of replacing parts, so specify what you are > looking for. If they do replacements often, they may also sell you the > J1772 gun they install as part of the quote.] > > It's not a difficult replacement, but hiring somebody else to do it is > going to add significantly to the cost (WAG: $100 truck roll fee + 50 to > do the swap out?). > > So I'd estimate you are looking at $250-350 to hire a "professional" to > do it with parts & labor....which is getting up in price to close to the > cost of a new EVSE. [Assuming it is not hard wired, you can just plug in > replace a new EVSE....but if it IS hard wired, it sounds like you'd be > hiring an electrician to swap out the whole unit.] > > > Jay > > > -------------- next part -------------- An HTML attachment was scrubbed... URL: <http://lists.evdl.org/private.cgi/ev-evdl.org/attachments/20241009/1d85a5e0/attachment.htm> _______________________________________________ Address messages to ev@lists.evdl.org No other addresses in TO and CC fields HELP: http://www.evdl.org/help/
