Charger shows E19; internal contactor pre-charge or inrush limiting error

Safety first: Pre-charge circuits handle high inrush currents. Isolate power and wait for capacitors to discharge before working inside the charger.

Step-by-step checks:

• 1. Observe behavior: E19 often appears immediately when attempting to close the main contactor. Note any unusual noises or smells.
• 2. Visual inspection (power off): Open the housing and locate the pre-charge resistor and associated relay (if present). Look for discoloration or cracking of the resistor body.
• 3. Measure resistor: With the resistor isolated, measure its resistance and compare to the specified value. An open or drastically changed value indicates failure.
• 4. Check pre-charge relay: Test the relay coil and contacts for continuity and proper operation.
• 5. Output short check: Verify that there is no short circuit on the output wiring or Type 2 socket that could cause excessive inrush.
• 6. Replace components: Replace a failed pre-charge resistor or pre-charge relay. If control timing is incorrect, replace or reprogram the main control board.

After repair, monitor the charger during several start cycles to ensure E19 does not recur.