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Excessive Thermal Stress / Overheating Housing
Charger housing becomes very hot to the touch during normal charging, even at moderate current.
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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
Undersized supply cable causing I²R losses, Loose high-current terminals inside charger, Degraded thermal interface on power semiconductors, Installation in confined or sun-exposed location
How to Fix / Troubleshooting
Safety: If the housing is too hot to touch comfortably, stop charging and investigate.
- Check cable sizing: Confirm that the supply cable cross-section is appropriate for the configured current and run length. Upgrade cable if undersized.
- Tighten terminals: With power off, open the charger and re-torque all high-current connections (L, N, PE) and internal busbars.
- Improve installation conditions: Provide shade, ventilation, or relocate the charger away from direct sun and heat sources.
- Reduce current: Temporarily lower the maximum current in the app and observe whether temperature remains within acceptable limits.
- Replace power board if damage is visible: If you see burnt marks or melted plastic near power components, replace the power board.
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Repair Difficulty
Medium
3/5
Required Part
Power Board / Main Terminal Block
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