EVpower
Member
- First Name
- Steve
- Joined
- Dec 24, 2023
- Threads
- 2
- Messages
- 20
- Reaction score
- 24
- Location
- Northern California
- Vehicles
- 2023 F-150 Lightning Lariat, Bronco II
- Occupation
- Electrical Engineer
- Thread starter
- #1
I want to share some tips on power cords for EVSE or Pro Power On Board use with the forum.
Buy extension cords based on the wire gauge (AWG) and needed length. I've noticed some manufacturers have gotten very creative with marketing cords which might be fine for intermittent use but are undersize for continuous vehicle charging current. The outside diameter of some cords can be misleading as well, with more plastic insulation and smaller diameter wire. If you need a long extension cord, spend the money for a larger wire gauge cable. The general rule of thumb is 12-gauge flexible extension cords on 20 Amp circuits and 10-gauge cable on 30 Amp circuits. 14-gauge cords are undersize for EVSE feeds.
Take the time to uncoil an extension cord when it is in use. That allows heat buildup in the cable to dissipate better.
If you are using the locking type plugs like the NEMA L14-30 on PPOB, be very careful not to bend the pins. They are easily damaged in normal handling while still being able to be inserted in the mating receptacle. The result is a melted plug and connector. I recommend a protective cover for the plugs. The best protection is a mating connector tied to the plug end with nylon line. You can also make a plug cover with PVC pipe. A water bottle with the ends cut off could avoid damage to an extension cord in the frunk or truck bed.
If you are making or repairing locking connector cables, be aware that the individual conductor twist reverses about every six inches. If you can't get the right color conductor on the correct pin, cut the outer jacket back six inches and try again. On a new cable, try the other end of the cut piece to get the connections right. Be very sure to check the torque on the connections more than once.
Merry Christmas,
Steve
Buy extension cords based on the wire gauge (AWG) and needed length. I've noticed some manufacturers have gotten very creative with marketing cords which might be fine for intermittent use but are undersize for continuous vehicle charging current. The outside diameter of some cords can be misleading as well, with more plastic insulation and smaller diameter wire. If you need a long extension cord, spend the money for a larger wire gauge cable. The general rule of thumb is 12-gauge flexible extension cords on 20 Amp circuits and 10-gauge cable on 30 Amp circuits. 14-gauge cords are undersize for EVSE feeds.
Take the time to uncoil an extension cord when it is in use. That allows heat buildup in the cable to dissipate better.
If you are using the locking type plugs like the NEMA L14-30 on PPOB, be very careful not to bend the pins. They are easily damaged in normal handling while still being able to be inserted in the mating receptacle. The result is a melted plug and connector. I recommend a protective cover for the plugs. The best protection is a mating connector tied to the plug end with nylon line. You can also make a plug cover with PVC pipe. A water bottle with the ends cut off could avoid damage to an extension cord in the frunk or truck bed.
If you are making or repairing locking connector cables, be aware that the individual conductor twist reverses about every six inches. If you can't get the right color conductor on the correct pin, cut the outer jacket back six inches and try again. On a new cable, try the other end of the cut piece to get the connections right. Be very sure to check the torque on the connections more than once.
Merry Christmas,
Steve
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