EvoCharge Overheating / Component Burnout

Burning smell or visible smoke from the charger during or after charging.

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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 terminal, Shorted internal component on control or power board, Overloaded circuit, Failing contactor or relay

How to Fix / Troubleshooting

Safety first: Immediately turn OFF the breaker and, if safe, unplug the vehicle. Do not attempt to continue using the charger until fully inspected.

  • 1. Do not open while hot: Allow the unit to cool completely before removing the cover.
  • 2. Inspect for damage: Once cool and with power OFF, open the EvoCharge unit and look for burned wires, melted insulation, or charred components.
  • 3. Tighten and repair wiring: Replace any burned wires and tighten all high-current connections. Use appropriately rated wire and lugs.
  • 4. Replace damaged components: Any burned contactor, terminal block, or board must be replaced with OEM parts.
  • 5. Root cause analysis: Have an electrician verify that the circuit is correctly sized and that there are no upstream issues causing overheating.

Do not ignore burning smells; they are an early warning of potentially serious failures.

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Repair Difficulty

Professional Required 5/5

Required Part

Main Power Contactor or Terminal Block
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