E05
Mini Output Overcurrent / Relay Protection Trip

Charging stops intermittently; E05 displayed; breaker remains on

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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

Short circuit or partial short in tethered cable, Internal contactor/relay contacts welded or degraded, Incorrect current setting in charger configuration, Faulty current sensor on Mini charger PCB

How to Fix / Troubleshooting

Warning: Overcurrent can overheat wiring. If you smell burning, turn off power immediately.

  • Check charger settings (if user-accessible): Using the Mini charger app or interface, verify that the maximum current is set according to the installation (e.g., 16 A, 32 A). Do not exceed the circuit rating.
  • Inspect cable for hot spots: After a short charge attempt, carefully feel along the tethered cable (without bending sharply). If any section is significantly hotter than the rest, the cable may be damaged internally and should be replaced.
  • Listen for relay click: When starting a charge, you should hear a distinct click from the internal contactor. Rapid repeated clicking with E05 may indicate failing contacts.
  • Power cycle: Turn off the breaker for 1 minute, then restore power and retry. If E05 recurs immediately, stop using the charger.
  • Technician checks: A qualified technician should measure output current with a clamp meter and compare to the setpoint, inspect the power contactor/relay block, and test the current sensor on the main PCB.

In most cases, the tethered cable or internal power contactor will need replacement.

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Repair Difficulty

Hard 4/5

Required Part

Mini EV Charger Power Contactor / Relay Block
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