Emporia Abnormal Arcing at Connector

Visible arcing or sparking when plugging in or unplugging the J1772 connector.

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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

Contactor closing too early or opening too late, Welded or sticking contactor, Damaged or contaminated J1772 pins, Vehicle inlet fault

How to Fix / Troubleshooting

Safety: Stop using the charger immediately. Turn off the breaker. Arcing can cause burns and fire.

  • Inspect J1772 handle and inlet: Look for pitting, burn marks, or melted plastic on the pins. Do not reuse a damaged connector.
  • Verify proper sequence (qualified person): The contactor should only close after the connector is fully inserted. If arcing occurs during insertion, the contactor may be welded or miscontrolled.
  • Replace damaged components: Replace the J1772 cable assembly if pins are damaged. Replace the contactor if it is welded or not opening correctly.
  • Test with another EV after repair: Confirm that no arcing occurs and that charging starts only after full insertion.
  • If arcing continues with new parts: The control board timing logic may be faulty and should be replaced.
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Repair Difficulty

Professional Required 5/5

Required Part

J1772 Charge Handle and Cable Assembly
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