Electrify America Overheating / Component Failure

Charger emits a burning smell or visible smoke during or after a charging session.

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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

Overheated contactor or terminals, Shorted power module components, Melted cable insulation, Foreign object burning inside enclosure

How to Fix / Troubleshooting

Safety first: Immediately stop using the charger. Turn off the breaker and, if necessary, call emergency services.

  • Step 1 – De‑energize: Turn off the dedicated breaker and do not turn it back on until the unit is inspected.
  • Step 2 – Visual inspection (after cooling): Once cool, open the enclosure and look for burned components, melted plastic, or soot.
  • Step 3 – Identify source: Determine whether the damage is localized to the cable entry, contactor, power module, or control board.
  • Step 4 – Replace damaged assemblies: Replace any visibly damaged components (cable, contactor, power module, control board) with Electrify America‑approved parts. In many cases, full unit replacement may be more economical.
  • Step 5 – Professional evaluation: Have a licensed electrician verify that the branch circuit wiring and breaker were not damaged by the fault.
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Repair Difficulty

Professional Required 5/5

Required Part

Power Module, Main Contactor, or Charge Cable Assembly
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