Thanks Phil, interesting about the winding issue.
I'm not buying a used cable for an important project involving someone
else's property, but if you have a link to a new one of the same
specifications (including the 25 feet), then I could consider buying it.
Josh
On 10/9/2024 9:18 AM, (-Phil-) via EV wrote:
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
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