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When EV Charger Installations Go Wrong : A Real Call-Out Case Study

With more homeowners switching to electric vehicles, EV charger installations are becoming increasingly common. Unfortunately, so are cases where chargers have been incorrectly installed, putting both property and safety at risk.

Recently, I was called out to an EV charger that had completely stopped working. What initially seemed like a simple fault quickly turned into a much more serious issue.

First Signs of Trouble

As soon as I opened the meter cabinet, I was greeted by a strong fishy, burning electrical smell — a tell-tale sign of overheated or failing electrical components. This immediately raised concerns, and power was isolated to investigate further.

What Went Wrong?
Upon inspection, several serious installation issues were identified:
• ❌ The EV charger was not installed to current regulations
• ❌ It was protected by an RCD only, with no Surge Protection Device (SPD)
• ❌ Although the enclosure itself was IP rated, a compression gland had been drilled into the top of the meter cabinet
• ❌ Meter tails and the EV supply cable were also brought in through the top of the unit
This setup allowed water ingress, with moisture tracking down the cables directly into the enclosure. Over time, this led to significant internal damage and ultimately a failure outside of the RCD, causing the charger to shut down completely.
An IP rating means very little if basic installation principles are ignored — gravity always wins.
Why This Is Dangerous
Water ingress combined with inadequate protection can lead to:
• Overheating and component failure
• Electrical arcing
• Fire risk
• Damage to expensive EV charging equipment
In this case, the RCD alone was not sufficient to protect against the fault that occurred.

 

The Remedial Work
To correct the issues and bring the installation up to current standards, the following remedial works were carried out:
• ✅ Installation of a new IP-rated internal enclosure to improve overall protection
• ✅ Correct routing of meter tails and EV supply cable through the bottom of the unit to prevent water tracking
• ✅ Replacement and correct termination of all affected cabling
• ✅ Installation of SPD protection
• ✅ Upgrade to double-pole RCBO protection
• ✅ Full testing and commissioning to ensure compliance with current regulations
The Result
The EV charger was safely restored, fully compliant, and back on charge within two hours. Most importantly, the installation is now safe, protected, and built to last.
Another happy customer — and a potential fire risk avoided.
A Word of Advice for Homeowners
If you’re considering an EV charger installation, or already have one fitted, ask the following questions:
• Is it protected by an SPD?
• Are cables entering enclosures from the bottom?
• Is the installation compliant with current BS 7671 regulations?
• Was it installed by a qualified, competent electrician?
Cheap installations often end up being the most expensive once remedial work is required.

 

Need an EV Charger Checked or Installed Properly?

At Bring It Ohm Electrical Solutions, EV charger installations are carried out correctly, safely, and in full compliance with current regulations — no shortcuts.

If you have concerns about an existing installation or are planning a new one, feel free to get in touch for honest advice or a professional inspection.

Written by Paul Cerri

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