FLO
Overheating Connector / High Contact Resistance
Charger’s cable or connector becomes very hot during charging; plastic may discolor or smell.
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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
Worn or loose contacts in J1772 handle, Corroded pins in vehicle inlet, Undersized or damaged cable conductors, Prolonged operation at maximum current in high ambient temperature
How to Fix / Troubleshooting
Safety first: Stop charging immediately if you notice melting, smoke, or burning smell. Turn OFF the breaker.
- Inspect connector: Look for discoloration, warping, or burn marks on the J1772 handle and pins. If present, the handle must be replaced.
- Check cable condition: Feel along the cable for localized hot spots or soft areas. Any such area indicates internal damage.
- Reduce current (if supported): Use the FLO app to temporarily lower the maximum charging current and see if temperatures remain acceptable.
- Have vehicle inlet inspected: If multiple EVSEs overheat when connected to the same vehicle, the vehicle’s inlet contacts may be worn or corroded.
- Replace affected parts: Replace the J1772 charge cable and handle assembly if any damage is found. Do not continue using a damaged connector.
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Repair Difficulty
Medium
3/5
Required Part
J1772 Charge Cable and Handle Assembly
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