A bit funny, a little scary, a little painful, and expensive story of short life and death of a three-year charging cable.

Summary: keep your charging cables dry (or use it as a quick water boiler, or fight global warming by plant cultivation)

As I have done a test of flexibility in -20C for Dostar/EV-Connectors (3x32A orange one) and Mennekes (the blue one), I used orange one today to charge my car.
As something „exploded” inside the plug and hot steam and boiling water spread onto my hand, causing scald (nothing dangerous of course), and breakers switched off, I decided to open both sides of the orange cable.

This cable is produced by Dostar (…/62196-2-Charging-Cable-Type–1031286… ) but you can buy it at many ev-cables shops (mine was bought 3 years ago at ev-connectors), you can also buy it at Farnell. Wow!
As you can observe (find in the attached link) – this cable, when mated (connected to car and station) offers IP55 protection. Theoretically, water projected by a nozzle (6.3 mm (0.25 in)) against enclosure from any direction shall have no harmful effects.
I used it interchangeably with blue cable from Mennekes I received in my car.
There was a lot of water inside. White plugs are paired from two parts and there is no seal in between – So even IP52 sounds optimistic (Vertically dripping water shall have no harmful effect when the enclosure is tilted at an angle of 15° from its normal position. A total of four positions are tested within two axes).
Water and dirt caused a short circuit, boiled water inside and sprayed hot steam.
Notice unusual method of shortening cables – by twisting them (same on both sides). Also, one screw inside the plug is missing (there are, or better to say – should be four screws at terminal plate lock).

There are „premium” cables available, where the whole plug is filled with an epoxy resin. It seems that some charging cables distributors found already, that Chinese letters “我在55小便” translate not exactly to European IP55, I highly suggest buying such resin-filled or better-manufactured cables instead of cheaper Chinese cables.
As the „Chinese IP protection” level seems to be far from reality, and TUV Rheinland certificate looks strange there. Hard to say, what does it certify, as even the IP protection level is not printed.

PS: Under the microscope you can see green algae, set up a colony just above the TUV logo, trying to replace the seal that man forgot.
Small, brainless creatures – and they bring so much good into this three-year, certified car charging cable.
I am sorry that I have to throw all my life together with the cable into the rubbish bin (of course, I will sort it – copper for metals, plastic housings for plastics, algae for organic, and TUV Rheinland and CE certificate for mixed rubbish).
Whom should I send a receipt for skin burn cream to?

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