NewMotion
Overheating Connector or Internal Wiring
Charger or cable becomes very hot to the touch during charging, possibly with a hot plastic smell.
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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 high-current connections, Worn or oxidized Type 2 contacts, Undersized supply cable, Continuous operation at maximum current in high ambient temperature
How to Fix / Troubleshooting
Safety first: If you smell burning or see smoke, stop charging immediately and turn off the breaker.
- Reduce current: In the installer or user settings, temporarily reduce the maximum charging current and monitor temperature.
- Inspect plug and socket: After cooling, check for discoloration or deformation of the Type 2 plug and socket. Replace any heat-damaged components.
- Tighten terminals: With power off, retorque all high-current terminals on the input block, contactor, and socket/cable connections to manufacturer specs.
- Check cable sizing: Confirm that the supply cable cross-section is adequate for the configured current and run length.
- Ventilation: Ensure the charger has adequate airflow and is not installed in a confined, unventilated space.
- Replace overheated parts: Any melted or charred socket, cable, or terminal block must be replaced.
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Repair Difficulty
Hard
4/5
Required Part
Type 2 Socket / Tethered Cable / Terminal Block
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