Rolec WallPod

EVSE Plug/Cable Replacement Instructions

NOTE:  Completing this procedure will almost certainly void your EVSE warranty!

Tools Required:-

No 2 posidrive screwdriver (ideally electrician’s)

2mm Flat/phillips  Screwdriver

4mm Flat screwdriver (ideally electrician’s)

Mains tester

(Possibly) 8” Adjustable spanner

Pair of ‘side cutters’

1/  ISOLATE THE EVSE (charge point box) from the mains supply.  Do so by switching off the mains at the relevant consumer unit (‘fuse box’).  Most EVSE supplies are wired via a separate isolation switch (NOTE: This is NOT the same as an MCB or RCD or RCBO but if the relevant device is a 2 pole one then this, when ‘Off’, will effectively isolate the EVSE).  If it is isolated, none of the status lights will be illuminated on the front panel.

2/  Confirm isolation from the mains by using a mains tester to MAKE SURE none of the wires to the EVSE are live (this may not be possible without first removing the EVSE front panel).

3/  Use a No 2 posidrive screwdriver to remove the 6 self-tapping screws  (usually about 4) from the EVSE front panel. 

4/  Remove the front panel.

5/  The inside of the EVSE looks like this...

6/  TAKE A PHOTO of the inside of the box to allow you to check your (completed) re-wiring is correct.

7/  Slacken the gland nut on the ‘Car Plug Cable Out’ gland (the one on the outside of the EVSE box)...

8/  a/  Slacken the 'Live' and ‘Neutral’ terminals (as marked in red in the photo above) using the No 2 Phillips screwdriver and the ‘Earth’ terminal using the 4mm flat screwdriver, and pull the wires out.  

    c/  NOTE THE POSITION OF and then slacken the ‘CP’ wire terminal using the small flat screwdriver and pull out the CP wire.

9/  Using the side cutters, carefully cut off the cable tie on the ‘Car Charging Plug Cable Inlet’ just inside the EVSE box.

10/  Gently pull the ‘Car Plug Cable Out’ cable ends out through the cable gland.

11/  Gently insert the ends of the new cable.  Staggering the ferruled ends of the conductors may make this easier rather than trying to do them all at once.

12/  Connect the Live, Neutral and Earth wires to their respective terminals.   All these 3 connections should be as tight as you can get them without allowing the screwdriver to slip on the screw-head.  Connect the ‘CP’ wire to its terminal.  The new CP wire may be a different colour to the original but it will be clearly marked ‘CP’.   It is ESSENTIAL that ALL these are correct.  If you mix them up you could not only damage your EVSE...


13/  Tighten the ‘Car Plug Cable Out’ gland nut such that the ‘Car Plug Cable Out’ cable cannot be pulled out using reasonable hand force.  The spanner may be required. 

14/   It is also good practice to tightly attach a stout (at least 6mm) plastic tie to the end of the ‘Car Plug Cable Out’ cable outer sheath just inside the gland nut to help prevent the cable pulling out of the gland (as shown in the photo).

15/  Replace the EVSE front panel.  Make sure the lid is properly in place before inserting and tightening the screws.   Do not over-tighten the screws. 

16/  Switch on the mains.

I strongly advise that after a week or so of heavy use (ie 10kWh or more of charging per day) the front cover of the EVSE be removed and the Live and Neutral connections be checked for any signs of overheating (‘sweating’ of the plastic insulation, browning or (hopefully not) charring or obvious ‘burning plastic’ smell.  If any sign of this is found, check the terminal is TIGHT!  Then check again after a similar period of use.  If heating is still found, consider replacing the affected component and/or re-doing the connection.


NOTE:  For liability reasons, I strongly urge you to undertake what follows ONLY if you are ‘suitably qualified’.  If you do something silly, you could very easily DIE!!!

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