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I have a hybrid vehicle that uses a "type 2" charging cable, but the cable is too short. It plugs in to a regular 13Amp UK socket in my garage. The problem is that, in addition to the usual 3 twin and earth cores, the cable also has 2 smaller cores which I believe are used for some charger control / diagnostics.

The plug it was attached to looks like an ordinary UK moulded socket but I can't get into it to see how it is wired.

Can anyone help ? Here are the relevant pics:

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  • \$\begingroup\$ Sounds like a hacksaw would come in handy. \$\endgroup\$ – Andy aka Aug 30 '20 at 8:36
  • \$\begingroup\$ @Andyaka You mean to take the moulded plug apart ? Yes, could do that. \$\endgroup\$ – Robert Long Aug 30 '20 at 8:41
  • \$\begingroup\$ You should be able to get a longer cord from the manufacturer. I'm sure the cords have accidents all the time, like being run over, or chewed by rats. \$\endgroup\$ – Andrew Morton Aug 30 '20 at 16:48
  • \$\begingroup\$ @AndrewMorton yeah, it's just that they are stupidly expensive (£185 or more) \$\endgroup\$ – Robert Long Aug 30 '20 at 17:11
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It looks like there is a plug overheat detection system, with something like a thermistor between the red and white wires. That will be buried inside the plug somewhere. If you don't connect the wires, then the charging unit will probably refuse to work.

You also have the problem that a standard 13A plug isn't designed to take 2.5mm² cables. While it may be possible to jam such a wire into a plug, the cord grip won't work.

Unfortunately, you chopped that wire off rather short. I suspect the only solution may be to strip the insulation off the stubby little bit of cable, and make a secure join to the end of a new 5-core lead.

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  • \$\begingroup\$ Thanks ! Yes, I now realise I should have cut it further back and used some kind of junction box :( \$\endgroup\$ – Robert Long Aug 30 '20 at 8:40
  • \$\begingroup\$ If I were to join the yellow cable with a normal 3 core heavy duty cord, and simply connect the small red and white wires from the yellow cable together in the junction box, it should still work, right ? But then I will lose the overheat detection ? \$\endgroup\$ – Robert Long Aug 30 '20 at 9:21
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    \$\begingroup\$ @RobertLong The problem is that we don't know exactly what component they used in the plug. If it's a thermistor, then the charger may refuse to start unless it sees a resistance that is in the correct range. \$\endgroup\$ – Simon B Aug 30 '20 at 9:27
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    \$\begingroup\$ @SimonB well an ohmmeter and some boiling water will enable an estimate of a thermistor. I'm not sure why he cut the cable , and didn't just make an extension/ adapter cable , (like the cable I have for my welder with a 10A plug and 15A socket.) It looks like the manufacturer has uprated the plug by adding thermal sensing. \$\endgroup\$ – BobT Aug 30 '20 at 12:29
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    \$\begingroup\$ Thanks Simon & @BobT the reason I cut the cable is that I was intending to use an inline junction box, IP55 rated because I sometimes charge it in the driveway so the cable can be exposed to rain. I was expecting it to be easy, and it's only when I cut it that I noticed the additional wires. \$\endgroup\$ – Robert Long Aug 30 '20 at 17:36

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