Audi
Localized Overheating / Potential Fire Hazard
Audi wallbox emits a burning smell or shows discoloration on the housing near the cable entry.
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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 terminal at cable gland or internal terminal block, Overloaded or undersized supply cable, Damaged insulation due to mechanical stress, Failing contactor or connector generating heat
How to Fix / Troubleshooting
Safety first: Immediately stop using the charger. Switch off the breaker and do not restore power until inspected.
- Visual inspection: With power off, open the housing and look for burnt insulation, melted plastic, or darkened terminals near the cable entry and terminal block.
- Tighten and re-terminate: An electrician should re-strip and re-terminate any overheated conductors, ensuring proper torque and using new ferrules if required.
- Assess cable size: Verify that the supply cable cross-section matches Audi’s installation requirements for the configured current and run length.
- Replace damaged parts: Replace any discolored terminal blocks, contactors, or cable glands. If the PCB or housing is significantly damaged, replace the affected assemblies.
Do not resume operation until a full safety check (including insulation and functional tests) has been completed.
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Repair Difficulty
Professional Required
5/5
Required Part
Supply Terminal Block / Cable Gland Assembly
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