Charger plug melt

[plukcc]

I have a problem here
The cable from the charger to the wall power plug is too short
Every time the heavy charger is hanging
And worry about this will shorten the life time of the cable and the power plug
And recently I found that the plug is so HOT that the plastic melt
Please advice what I should do

[Brammofan]

I'd recommend talking to your dealer or directly to Brammo customer support.

[protomech]

Does this happen in every socket, or a particular mains socket?

Heating at the wall plug indicates the plug is making a high-resistance contact. It's possible that the plug or socket is physically malformed, or that the plug blades are dirty or corroded .. or perhaps there's dirt or foreign debris in the socket itself.

The Empulse will pull pretty hard from the socket; heating that might be acceptable when a 60 watt lightbulb is plugged in (0.5 A at 120 V) will be significantly hotter and potentially causing the melting when the Empulse is plugged in (likely 11-12 A at 120 V).

[plukcc]

So far I charged it in 2 public car park
And it got the same issue
Just afraid the weight of the charger may cause it happen as the charger is hanging
All the weight is on the plug
FYI most of the HK plug is 13A while I see the display of the bike is drawing 24A

[protomech]

This is the portable J1772 EVSE, correct? And when you say "the plug" you mean the plug going into the mains socket, not the plug going into the bike?

Pretty cool that it'll pull 13A on 220V .. but I guess the mains-side plug is not up to the task.

13A @ 220V = 2.9 kW from the wall!

The bike's display is DC amps at the battery. So if it's @ 105V DC, it's charging at 2.5 kW DC .. just about as fast as a typical J1772 EVSE.

[plukcc]

This is the portable charger came with the bike
Yes the plug means going into the main socket
So should I remove the melted  plastic on the plug first
If there any portable charger that the cable going into the main socket is longer say 5 feet
Then I can place the charger on the ground or hang it on the bike

[protomech]

Do you know what model of EVSE you have? Or can you post a picture of the entire unit?

Aerovironment recently announced a more compact dual-voltage charger, though I suppose you only need 240 volts.
http://brammoforum.com/index.php?topic=2418.0

However, Brammo should replace your EVSE if it is defective.

[plukcc]

this is my version
but that will be definitely a very good new if there is a smaller version, may i swap it?

and i wish we will have a new design of seat so that we can put this charger under it ^^
(hate to carry a back pack when riding, looks silly)

in deed, only a few car parks out of the hundreds got J1772 installed, the rest only provide a normal 13A socket

[plukcc]

Good news
I use a hook to hang the charger
And use another socket
The plug and the cable towards the wall is warm, at least not hot this time, but the cable towards the bike is cold
Having said that, is that warm still not normal ?
and unfortunately, i hardly can hook up the charging unit at most of the public car park in hong kong and amount all those hundreds of car park that provide charging, only a few of them got J1772 socket, the rest only provide 13A socket

[plukcc]

this is the most common power socket that they will build in car parks
and they will not build a hook next to it for me to hang my charger

[Shinysideup]

Use an extension cord.

 This site has a chart to show you how to pick the proper gauge of wire for the load and the length of the cord:

http://www.homedepot.com/c/factors_to_consider_when_choosing_extension_cords_HT_BG_EL

I know the Clipper Creek instructions say not to use an extension cord, but I've used a 15 foot 14 gauge cord rated at  a continuous 1875 watts.  I use it at friend's garages to get out to my bike. At home, I plug into the wall and use a hook to hang the CC. I've been using the cord for about a year without any issues.

For your purposes at public plugs, you may want to play it very conservatively and make up a shorter length of 12-gauge cord with heavy duty plugs attached. 10 gauge is difficult to handle, much less stow.

Whatever you choose, I'm speaking only of my personal experience. I'm neither an electrician nor an engineer,  I'm not responsible for any damage to you, the bike, the charger, nor any buildings, public or private!

[plukcc]

Thx for the advice, but I already feel very clumsy carrying a backpack with charger
And now I need an extra extension cord .....

[Shinysideup]

I have a problem here
The cable from the charger to the wall power plug is too short

If this is your problem, a short extension cord solves it. If your problem is carrying it in a back back and feeling clumsy, use a tail bag or soon-coming side cases to carry it.

[plukcc]

Can't wait for the side case