ABB Intermittent Charging / Session Dropout

Charger starts charging but stops after a few minutes without any error code; LEDs may show normal state.

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Safety Warning

This repair may involve working with high voltage components or water connections. Always unplug the appliance before removing any panels.

If you are not confident in your ability to perform this repair safely, we strongly recommend contacting a professional technician.

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Possible Causes

Loose internal power connections causing voltage dips, Overheating of cable or connector, Intermittent control pilot connection, External load management limiting current to zero

How to Fix / Troubleshooting

Observation: Note whether the vehicle or charger reports the stop; this helps locate the fault.

  • Monitor temperature: During a charging attempt, periodically feel the cable and connector (without touching metal contacts). If they become very hot, stop using the charger and inspect for damage.
  • Check for loose wiring: With power off, tighten all input and output terminal screws inside the ABB charger.
  • Disable smart features: Temporarily disable any load management, scheduled charging, or external control to rule out software-driven stops.
  • Test with another EV and cable (if detachable): This can isolate whether the issue is with the charger, cable, or vehicle.
  • Service inspection: If dropouts persist, have a technician check the control pilot circuit and power module for intermittent faults.
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Repair Difficulty

Medium 3/5

Required Part

Output Terminal Block / Tethered Cable
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