Picking up the story where I left off.
If you’re not interested in my ramblings, scroll to the end where I sum up my main findings.
On closer inspection of the cable, I discovered the CP pin on the plug was fully 10 mm deeper recessed than the other pins. The sockets on the charger plug all seemed to be at the same depth.
I reckoned I had discovered the problem (at least one of them).
The other possibilities seemed to be the car, and me, both common factors.
I phoned EV Connectors and requested uplift of the cable and a full refund. I said about the difference in depth of the pins, but they said that was normal.
They suggested it might be my vehicle and perhaps I should get that checked.
I decided to cough up the extra cash and buy the Mitsu cable, then if I did have to take it to a dealership, they couldn't blame the cable.
In the meantime I searched online to try and find diagrams or mention of this recessed pin.
Found diagram of pin connections and discovered the rogue pin was for control confirmation. (CP)
[One of the two smaller pins, both at the top. The other is PP for connection confirmation.]
I understood anyway that the charging pins did not become active until the relevant signal was received from the vehicle being charged.
The other pin connections are, if you are interested:
PE(Protective Earth) in the centre; then L1, L2 and L3 (live for each phase, ie can accomodate three phase) and N neutral.
All pins have insulated tips apart from PE (protective earth)
I skimmed and downloaded lots of diagrams and specs, including the IEC 62196-1
<http://www.inmetro.gov.br/barreirastecnicas/pontofocal/..%5Cpontofocal%5Ctextos%5Cregulamentos%5CSAU_357.pdf>
Plenty of dimensions, but no side view of pin location or any mention the recessed pin. (It could be there and I’ve missed it – please let me know of you know of it or find it)
When I got the Mitsu cable, you've guessed it, it also had this pin recessed!
On the plus side the cable was much thinner, so the entire package was much neater (see photos).
It doesn't have a dust cap on the charger end, but the car end plug is rubberised and waterproof looking and feeling.
Trying the same public charging station and my garage wall charger I was coming up against the same problems.
I decided to move the plug from one side of a public charging post to the other and low and behold it worked!
I examined the pin socket depths on the public charging station socket and again they all seemed the same depth. However paying closer attention, I found when I inserted the plug it went fully home, right up the the flange, whereas when it was inserted into tethered cables at home and at charging points , it inserted but not fully up to the flange.
Eureka!
I reckon this is the reason for the recessed CP pin, so that if you try to plug a cable plug into a female cable plug, it will not work due to the lack of passage of a Control Confirmation signal.
I phoned Charge Master and asked. They confirmed it would not work, plugging into a tethered cable, but couldn’t elaborate any further.
Main points are summed up below:
EV Connectors
No EV Connectors cables were faulty;
EV Connectors accepted my returns without quibble and did not charge me return carriage.
They have given me a full refund.
They had tested the second cable before dispatch (Although this wasn’t made clear to me and nothing written to this effect on the packing note).
After I requested return of the second cable they tested my first return and found it to be okay.
They advised I should consider having the car tested.
Comparison of EV Connectors cable with Mitusbishi one.
Price: EV Connectors £184; Mitsubishi £299 ie £115 more !
EV Connectors cable has dust cap on each plug, Mitsu one only on the Type 1 plug (Car end)
Mitsu Type 1 plug is a rubberised waterproof looking and feeling plug.
The EV Connectors flex is much thicker and bulkier.
I assume it has all three phase pins connected. Mitsu one only has one phase pin.
(EVC one is presumably suitable for a wider range of applications.)
Lessons learned
The CP (Control Confirmation) pin is about 10mm deeper recessed than the other pins.
This is to prevent cables being connected to cables.
If a plug is inserted into a plug (female ) on another cable (eg tethered one at a charging point) it does not go in far enough for the CP pin to engage.
Consequently charging does not commence.
Some charging stations are faulty, even when there is nothing to indicate this.
Even with two identical charge points on the one pillar, one may operate whilst the other does not!
Don't try out new things in the freezing rain when its cold and you’re tired!!
Next steps
Try and organise a wall charger with a Type 1 tethered cable. Wish me luck!
Thanks again to those that offered trying out their cables, or swapping to test.
PS If someone can tell me how to insert/upload images, I'll post a photo of both cables for comparison and a plug pin diagram.
PPS Sorry if it all seems pretty obvious in retrospect. It has and still is a steep learning curve for me!
