OpenEVSE
Contact Erosion / Load Disconnect Under Power
Visible arcing or sparking at the J1772 connector when plugging in or unplugging, sometimes accompanied by a popping sound.
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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
Contactor not opening before unplugging due to stuck relay, Worn or pitted contacts in J1772 handle, Plugging/unplugging under load due to pilot/proximity fault
How to Fix / Troubleshooting
Safety first: Arcing is dangerous and can damage the connector. Stop using the EVSE until resolved.
- Step 1 – Observe behavior: Ensure that charging has fully stopped (EVSE indicates not charging) before unplugging. If arcing occurs even when EVSE shows idle, the contactor may be stuck closed.
- Step 2 – Inspect connector: With power OFF, examine the J1772 pins for pitting, blackening, or deformation. Replace the cable if contacts are damaged.
- Step 3 – Test contactor: Follow the stuck relay troubleshooting steps to confirm the contactor opens correctly when commanded.
- Step 4 – Replace components: Replace the J1772 cable assembly and/or contactor as needed to ensure the connector is never live when unplugged.
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Repair Difficulty
Hard
4/5
Required Part
J1772 Charge Cable Assembly
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