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@Antony Day

Can you post a picture?  

Assuming you have our kit with the Struthers Dunn relay... There are a couple areas to keep clear so the relay will close. The mechanical hinge for the contacts goes across the relay and makes a 90 down the left side. It is important to keep this area clear so the contact mechanism can move freely.

There is also a ring retainer below the contact arm. You can see it by lifting the top contacts up a bit. If this becomes dislodged or is not properly seated it can interfere with the relay closing.

@Antony Day 

Please check the retaining ring. Your issue has to be either a mechanical blockage or an electrical connection. 

The relay coil connects to the OpenEVSE controller on a 3 pin connector, one pin is open. This is a second relay channel. You can move the black wire from the side it is on to the open position. 

@Anthony the command for relay delay and power is $Z0

Here is a picture of the retaining ring. It should be easy to tell if the relay moves freely by pressing the contacts down by hand (with the power off).

@Antony -The odds that both relay outputs on your controller are bad are essentially zero. We have never seen this.  We can exchange controllers if you wish however we do not think it will resolve your issue.

Older WiFi firmware does not update the current value immediately, even though the current was written to the controller. You can verify this using the RAPI commands. 

Send a set current (this example sets 24A)

$SC 24

The controller should respond $OK

Then send the get current command

$GC

It should respond with an Ok and 24

The latest WiFi firmware is here:

https://github.com/OpenEVSE/ESP32_WiFi_V4.x/releases

We are making progress, your issue with the handle seems to be resolved now. 

We clearly understand the "No Ground" the issue.  Assuming your earth ground is good. The false positive can only be two things, electrical or mechanical.

Electrical -  "OpenEVSE now goes ready -  plug car in - connected - KLAK" proves the output on the controller is working. I am not very familiar with the "EU firmware" you have loaded it likely does not have Adjustable relay power enabled however if it does, adjustable power was disabled in software with $Z0 command.

Mechanical - The pictures show no wires are providing a physical blockage. If the retaining clip is Okay and the relay is smooth easy to close by hand then the only other mechanical issue we have seen is the relay contact gap is too large. The Gap should be about 2mm. The gap can be adjusted by squeezing the top contact plate and the stop on the side.