PPC-13
Pod Point
Welded Contactor / Stuck Power Relay Detection
Charger shows 'Relay Welded' or 'Contactor Stuck' error, charging disabled for safety
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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 contacts welded due to overload or short circuit, Mechanical failure of contactor, Faulty contactor feedback sensing circuit on PCB, Excessive inrush current from vehicle
How to Fix / Troubleshooting
Safety: A welded contactor can leave the output live even when the charger thinks it is off. Do not use the charger until repaired.
- Step 1 – Switch off supply: Turn OFF the dedicated MCB/RCBO and any local isolator to ensure the charger is fully de‑energized.
- Step 2 – Do not attempt to charge: Do not reconnect a vehicle or attempt to reset the error repeatedly.
- Step 3 – Technician inspection: A qualified electrician should open the unit, verify whether the contactor opens and closes freely, and test for continuity across the contacts when de‑energized. If continuity remains, the contacts are welded.
- Step 4 – Replace contactor: Replace the contactor with the exact Pod Point‑specified model and rating. Inspect surrounding wiring for heat damage and replace as necessary.
- Step 5 – Verify feedback circuit: After replacement, confirm that the contactor feedback circuit on the PCB correctly detects open/closed states. If not, the PCB may also require replacement.
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Repair Difficulty
Professional Required
5/5
Required Part
Main Power Contactor / Relay Assembly
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