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Damaged charging plug – replace, don’t repair

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Accidents happen – but sometimes a quick fix is not the answer.

EV charging plugs are more complex than standard mains ones – so if you damage one, it’s better to replace than try to repair. In this video, watch as Laura, our Delphi expert, explains why.

Power Electronics Vehicle Electronics & Engine Management How to Distributors Shop Owners Technicians 1 min read

Why is a charging plug more complex than a mains plug?

A charging plug has earth, live and neutral wires as per mains, but it also has two additional wires for measuring the temperature of the plug. This is because heat can easily build up over the long period of charging, and by monitoring the temperature the charge level can adjust to avoid overheating.

How do I tell if an EV charging plug is damaged?

The most obvious way to tell is visually – if the exterior has been damaged by accident. However, other symptoms of a damaged charging plug include little or no power output, inconsistent charging, or intermittent functionality.

What is the lifespan of an EV charger?

Wall-mounted and Level 1 EV chargers typically last for around 10-15 years. Level 2 and 3 chargers are designed for a longer lifespan of 20 years or more. A standard cable used with EV chargers typically lasts for over 10,000 full charges.

Can I use an extension cable for EV charging?

It’s always best practice to plug directly into the mains. Standard household extension leads are not designed for several hours of EV charger use.

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