Replacing a sealed plug for an EV-charging certified cable reel?

[ginsublade]

Hello everyone,


I just bought an EV and trying to figure out how to charge it safely. I live in a rented first floor flat with a garage right below me. I don't have any sockets in my garage so my plan is to run a cable reel from the flat into the garage and then chage my EV with a 3 pin charger connected to the cable reel. Yes, I know it's slow but I really don't mind. I live in London and have to drive for work but only a few miles every day, which means the slow charging is plenty fast.


What I have already done: I replaced the socket inside the flat that I am plannign to use with a EV-charging approved socket (I forget the BS certification number, but it does have it) and I have drilled a hole into the floor connecting to the garage that is wide enough to fit a cable through it.


The problem is that the only EV-charging certified cable reels I can find at Screwfix are the Stanley ones and they have a sealed plug. This is a problem because in order to be able to run the cable through the hole in the floor I have to remove the plug first, and if I do that it would mean cutting it off altogether seeing as it is sealed.


So my question is, is that safe to do? Can I just cut it and replace it with a removable plug? Is that sealed plug special in any way? What is the purpose of fitting a sealed plug in the first place? Why would they not go with a removable one? Would removing it affect the ev-charging certification? Should I be looking for any sort of particular plugs to replace it with? The reel I'm looking at is this:

https://www.screwfix.com/p/stanley-13a-4-gang-15m-cable-reel-2-1a-2-outlet-type-a-usb-charger-240v/203va

Any help would be greatly appreciated.

Thank you!

 

[plugwash]

I would consider a claim of "suitable for EV charging" without any reference to a particular standard as meaningless BS.

If I had to use an extension lead for EV charging I would make one up in the required length with 2.5mm flex and permaplug plugs and sockets. I would *not* use a reel.

 

[ginsublade]

I would consider a claim of "suitable for EV charging" without any reference to a particular standard as meaningless BS.

If I had to use an extension lead for EV charging I would make one up in the required length with 2.5mm flex and permaplug plugs and sockets. I would *not* use a reel.

Hey, that's very helpful actually; thank you! Making one myself does sound better and also cheaper.
So just to clarify, I could get this, this and this (but shorter), and it would be a suitable combination? The plug and socket seem straightforward enough, it's the cable type I want to make sure I got right. Thanks again!

 

[flameport]

Those items are fine - however the main concern is not the cable (provided it's the correct size) it's the 13A plug.

Most charger cables have a thermal monitor in the plug so it will switch off if it overheats.
By using an extension there is no such protection at the plug end of that extension, so if the plug overheats it will melt and possibly cause a fire, and that end will be inside your flat.
Ways to mitigate this -
1 use a thermoset plug such as the MK 646, these do not melt when overheated. They are of the type that shatters into pieces when dropped rather than the bendy melty type of material.
2 Don't use a plug at all, with 2.5mm² it could be connected to a 16A or 20A circuit via a 20A isolator switch or similar.
3 an FCU could be used, however the heating problem is partly due to the fuse in the FCU / plug, so that might not be ideal, although they are generally made from thermoset materials so won't melt when overheated.
4 Depending on distance and exact locations, there is the option of extending from the existing socket using fixed wiring, such as 2.5mm² T&E inside PVC conduit and installing the new socket inside the garage as a permanent item.

 

[ginsublade]

Those items are fine - however the main concern is not the cable (provided it's the correct size) it's the 13A plug.

Most charger cables have a thermal monitor in the plug so it will switch off if it overheats.
By using an extension there is no such protection at the plug end of that extension, so if the plug overheats it will melt and possibly cause a fire, and that end will be inside your flat.
Ways to mitigate this -
1 use a thermoset plug such as the MK 646, these do not melt when overheated. They are of the type that shatters into pieces when dropped rather than the bendy melty type of material.
2 Don't use a plug at all, with 2.5mm² it could be connected to a 16A or 20A circuit via a 20A isolator switch or similar.
3 an FCU could be used, however the heating problem is partly due to the fuse in the FCU / plug, so that might not be ideal, although they are generally made from thermoset materials so won't melt when overheated.
4 Depending on distance and exact locations, there is the option of extending from the existing socket using fixed wiring, such as 2.5mm² T&E inside PVC conduit and installing the new socket inside the garage as a permanent item.

Thank you so much, that is so helpful indeed. At the moment I am not able to do any major work such as messing with the circuit board or making any permanent changes (other than upgrading the socket to the ev-charging certified one), and also I am not an expert so I thought that running an extension would be the easiest thing to do. The thermoset plug suggestion sounds great though, just to confirm are you referring to this model? My only concern is that according to the spec sheet, the maximum cable size for these is 1.5mm. Would that be enough? My car charger pulls 2.4kW and the total cable length (including the car charger) would be no more than 15-20m.

 

[Rodders53]

Ignoring the electrical safety side wrt plugs, sockets and fuses when running at 10 Amps for very long periods:

Have you got Landlord (and building Freeholder) permissions to break though to the (presumably) fire-protected integrated garage from your dwelling and install this cable? Plus, how do you plan to re-instate the fire protection once the cable is in place (and repeat if/when removing the cable)?

Do consider fitting a smoke/fire alarm in the garage if there isn't one already.

Many reasonable Landlords would allow a tenant to pay for installation of a proper EV charge point or even a simple garage socket (at tenant expense).

 

[EFLImpudence]

I live in a rented first floor flat with a garage right below me. I don't have any sockets in my garage so my plan is ...

Have a socket or two installed in the garage - simples.

 

[flameport]

just to confirm are you referring to this model?

That is the one.
1.5mm² flex is rated to about 16 amps, so plenty for a 10A charger.
BS1363 plugs generally won't be usable with flex larger than 1.5mm² as there is no need for such things.

 

[ginsublade]

That is the one.
1.5mm² flex is rated to about 16 amps, so plenty for a 10A charger.
BS1363 plugs generally won't be usable with flex larger than 1.5mm² as there is no need for such things.

Hi again mate. Ok, thanks for all the help. I'll get on it!
I just had an idea though. What if I just cut the charger cable and extend it, removing the need of an extra plug and socket? I could keep the original charger plug (it's one of those sealed ones, it also has BS 1363/EV written on it, which as far as standalone plugs go, I couldn't find any certified to the EV standard!) but just extend the cable with 1.5mm flex and crimp the cables at both ends. It would obviously void the ev charger warranty which I don't mind, but would that be safe? I don't see why not seeing as the cable running from the charger box to the plug is just a regular 3 core flex cable right? It would probably be the solution adding the least extra resistance in the system, wouldn't it? If it makes any difference, this is the charger I have:

Masterplug EV Charging Cable for Electric and Hybrid Vehicles, 10 Metres, Mode 2, Delay Charging Function, 3 Pin UK Plug to Type 2 Car Charger, Language Options, 2.4kW, EVCM221010-MP2 : Amazon.co.uk: Automotive

Masterplug EV Charging Cable for Electric and Hybrid Vehicles, 10 Metres, Mode 2, Delay Charging Function, 3 Pin UK Plug to Type 2 Car Charger, Language Options, 2.4kW, EVCM221010-MP2 : Amazon.co.uk: Automotive

www.amazon.co.uk

Thanks for all your help mate!!

 

[flameport]

For those that have temperature monitoring in the plug, the flex will have additional wires for the temperature sensor.
Some don't have that, but if you cut the plug off and find that it does, you have just destroyed it for no reason.