Charger housing becomes unusually warm or hot to the touch during normal charging.

Safety first: If the enclosure is too hot to touch or you smell burning, switch off the charger at the breaker immediately.

• Step 1 – Check installation environment: Ensure the charger is not exposed to direct sun for long periods and that recommended clearances are maintained.
• Step 2 – Reduce current (test): Temporarily lower the maximum charging current in the Alfen configuration and observe if temperature decreases.
• Step 3 – Inspect internal connections: With power OFF, open the charger and check all line, neutral, and earth terminals for tightness and signs of overheating (browning, melted insulation).
• Step 4 – Examine contactor: Look for discoloration or warping around the contactor. Replace if signs of overheating are present.
• Step 5 – Clean dust: Remove dust buildup that can trap heat, using a dry cloth or compressed air.
• When to call a technician: If overheating persists at rated current with all connections tight, a technician should evaluate the contactor and internal wiring and may need to derate or re‑cable the installation.