Electrical help

if you run heavier enough conductors you can check with an electrical supply house if they have 100% continuous load rated circuit breakers designed for your panel.
 
You assume that it is not overheating, when the evidence suggests that it is, in fact, overheating.

I would not rule out improper wiring. I would not rule out cheap parts, developing corrosion, and/or pitting,
The attitude is interesting. I get saving $, but. Hmm

I would assume nothing, and indeed overbuild. If that is true continuous current draw at 16A and just go with a 12G pair......I would assuredly have those wires very isolated if you follow.
 
Installed the new outlet and plugged in the charger. The battery was pretty full but it still showed a 1.5 hour charge time. Checked it out at the 1 hour mark and the plug was cool to the touch. So I guess that the outlet had gone bad. To all who assume that I have no idea how to wire an outlet you can get off your soap boxes. My connections to the old outlet were wire twisted around the screw and they were solid. The new outlet I couldn't do the wire twisted around the screw as the screws weren't long enough to do that. They had back holes that went up to the screw and a plate that the screw screws into. Tightened it down and all is well. I will have to keep an eye on it to see if the same thing happens in the future. Also I will have to charge the battery again on Tuesday after work and that will be the ultimate test as that should be a 4 hour charge.

Don
 
Installed the new outlet and plugged in the charger. The battery was pretty full but it still showed a 1.5 hour charge time. Checked it out at the 1 hour mark and the plug was cool to the touch. So I guess that the outlet had gone bad.

Don

You are not alone with this. Glad to hear the success.
EV charging highlight the shortcomings of many part choices, part quality and installations. You can do everything right and still have thermal problems over time. The ratings of cords, wires, outlets and breakers obviously don't work perfectly for EV charging. As I am sure you know the rule of thumb is 125% oversize. In my opinion, that's not enough.
 
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Which Leviton receptacle did you originally use? I see 5821 at Home Depot which is supposedly commercial grade:

https://www.homedepot.com/p/Leviton...hite-1-Pack-05821-0WS-R52-05821-0WS/100356999

Interesting that it couldn't handle the continuous load. Good to know that the industrial grade 5461 holds up

https://www.homedepot.com/p/Leviton...eptacle-White-1-Pack-05461-W-5461-W/301207446
Yeah not really sure which one I had. I just took it out of the garbage to investigate and cannot find any identifying numbers. I do see it is spec grade so there is that. I am not sure that the one I ended up getting is actually better than the old one or not. But it is working correctly. I would really like to find one that is leaps and bounds better than what I have now though. I really don't want to have to replace the outlet every 5 or 6 months.

Don
 
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