Megear Intermittent Connection / Thermal Cutback

Charger intermittently stops charging without any error code; charging resumes if unplugged and replugged.

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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 internal terminal screws, Overheating plug blades at outlet, Marginal relay contacts on relay board, Temperature sensor intermittently opening

How to Fix / Troubleshooting

Safety first: Turn off power before tightening any terminals or opening the charger. Overheated connections can be very hot.

  • 1. Check outlet and plug temperature:
    • After charging for 15–30 minutes, carefully feel the outlet and plug (without touching metal prongs).
    • If they are very hot to the touch, stop using the outlet and have it replaced.
  • 2. Tighten internal terminals:
    • With power off, open the Megear housing.
    • Tighten all line, neutral (if present), and ground terminal screws.
    • Inspect for discoloration or melted insulation around terminals.
  • 3. Inspect relay board:
    • Look for signs of overheating on the relay contacts and PCB.
    • If present, replace the relay board.
  • 4. Temperature sensor wiring:
    • Ensure the thermistor or temperature sensor is firmly attached to the heat sink and its wires are intact.

If intermittent stops continue, log the times and conditions and consult Megear support; a failing relay or control board may need replacement.

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Repair Difficulty

Medium 3/5

Required Part

Megear Relay Board
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