myenergi
Overheating of Cable or Internal Terminals
Zappi or its tethered cable becomes unusually hot during charging
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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 terminal screws on main terminal block, Undersized supply cable, Damaged or worn Type 2 connector, High ambient temperature and poor ventilation
How to Fix / Troubleshooting
Safety first: If you smell burning or see smoke, isolate power immediately and do not use the charger.
- 1. Stop charging: End the charging session and allow the unit and cable to cool.
- 2. Inspect cable: Check the tethered cable or plug for softening, discoloration, or deformation. Replace if any damage is found.
- 3. Check terminals: With power off, open the Zappi and inspect the main terminal block for signs of overheating. Tighten all connections to specified torque.
- 4. Verify cable size: Confirm that the supply cable cross-section matches the current rating and run length.
- 5. Reduce current: Temporarily lower the max current setting and monitor temperatures during a test charge.
- 6. Replace damaged parts: If the terminal block or connector shows heat damage, replace the affected components before using the charger again.
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Repair Difficulty
Hard
4/5
Required Part
Tethered Cable Assembly
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