Charging cable repair ?

Big Lar

So, daughters dog chewed 32A type 2 charging cable.

Shooting the dog is not allowed I am told so possible to replace the cable with SWA or something ?

handpref

https://www.boards.ie/discussion/2058323294/charging-cable-repair

No easy fix there Lar, specialist crimps needed for the internal connectors on both ends. Cable could be fine, however all you need is the tiniest bit of damage internally and you’ll blow yourself, your car or the gaff.

There was Phil in Electric Autos who magicked repairs for people in the past, me included but unfortunately Brexit ended the best independent EV company Ireland had ever seen.

...Ghost...

https://www.boards.ie/discussion/2058323294/charging-cable-repair

Not really an option. It's a sealed head. What type of charger is it?

I have a 5M length from my Hypervolt. I changed it out for a 7.5M one. The supplier should be able to sell you replacement cable. If it happens to be a HyperVolt, send me a PM and I'll sell you my 5M cable 😃

Buffman

AFAIK SWA charging cables are not readily available, I've never seen any for sale anyway. The issue is it's not just ordinary bog standard 3 or 5 core 6mm power cable, there's also the 1 or 2 control cables (PP/CP) running along it.

I'd say short term solution is keep the new cable well rolled up out of the way when not in use and keep the dog locked up away from it while charging.

I'd reckon that cable is beyond economic repair, what you'd pay to get it fixed would buy a replacement. Tell her to put it up on Adverts for a few € and someone might take it for parts or a DIY fix.

Big Lar

Tried taking apart the existing plugs and as @...Ghost... had mentioned above the plugs seem to be ultrasonic welded sealed.

Have done a bit of research since, can get SWA cable here. I have hydraulic crimp tool here so no problem with crimping on new ends.

Can also buy plugs on the internets, Aliexpress

Insulation tape is in place for the moment as after removing the cover and its just the insulation on one core that has been damaged but the core is still intact, But I reckon that I will buy both plugs and then make two smaller cables as in fairness to the dog he chewed it around the middle.

zg3409

I got a brand new 5m type 2 32 amp cable for about 80 euro delivered from.done Amazon seller so hardly worth the risk and effort.

As said there is extra control wires. You could join/shorten in a plastic junction box with IP67 glands but it would be a large box inline and not ideal. There is also the extra risk of it leaking or not surviving getting driven over by another car.

In terms of dog proofing you could possibly get flexible trunking or similar and cut a slot down the side of it and slip it over the cable to make it more hardened for next time. Some brands have heavier cables and 3 phase cables are typically chunkier which might survive better next time.

slave1

was about to post what zg just mentioned, I'd think about a blank length of SWA and slip over current cable, no matter what you do you are wasting your time replacing this cable or putting another non-dog proof compromise in place as it will just happen again, you will not be able to neatly "wind up" "reinforced" cable will be your next quandary

Buffman

https://www.boards.ie/discussion/comment/121389443#Comment_121389443

The only issue I see with that SWA cable you've linked is it's cat 5 cable on it designed to give hard wired internet connectivity to the charger from the house in 1 cable, rather than having to run 2.

The main issue is the pilot cables are normally 0.5mm whereas each individual Cat5 cable is only AWG34 which is around 0.16mm. There would be spare cables in the cat 5 so I guess you could group them together to compensate, but it's messy.

Also, when it comes to the plugs from Ali and anywhere else, in my experience they don't come with the PP-PE resistor which is required to tell the car/charger what size cable is plugged into them. (680Ω resistor for a 16A cable and 220Ω for a 32A cable).