ChargePoint
Overheating Component / Insulation Breakdown
Charger emits a strong electrical or burning smell during or after charging; may or may not show errors.
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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 high-current connection, Failing contactor, Overloaded wiring, Internal component failure on power board
How to Fix / Troubleshooting
Warning: A burning smell indicates a potential fire hazard. Stop using the charger immediately.
- Step 1 – Stop and de-energize:
- Unplug the vehicle.
- Turn OFF the breaker.
- Step 2 – Visual inspection (qualified):
- Open the housing and look for discolored, charred, or melted components, especially around the input terminals, power contactor, and power board.
- Step 3 – Tighten connections:
- Check torque on all high-current lugs and bus bars; retighten to spec.
- Step 4 – Replace damaged parts:
- Replace any overheated components, including the power contactor or power board as needed.
- Step 5 – Do not reuse until repaired:
- Do not restore power until all damage is corrected and the unit passes inspection by a qualified technician.
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Repair Difficulty
Professional Required
5/5
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