Rolec Overheating / Arcing at Connections

Burning smell or visible scorch marks around the Rolec charger or its cable during or after 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 supply or load side, Damaged or undersized cable, Worn or contaminated Type 2 socket contacts, Failing main contactor with pitted contacts

How to Fix / Troubleshooting

Safety first: Immediately stop using the charger. Isolate power at the main switch and do not re‑energise until inspected.

  • Visual inspection (power off): Open the enclosure and look for burnt insulation, blackened terminals, or melted plastic around the contactor, terminal block, and cable entries.
  • Check cable condition: Inspect the tethered cable and plug for discoloration or deformation near the plug end.
  • Tighten and clean: Replace any burnt components. Tighten all remaining terminals to the manufacturer’s torque specification. Do not reuse badly pitted or burnt contactors or sockets.
  • Replace damaged parts: Install new contactor, terminal blocks, or Type 2 socket as required using Rolec‑approved parts.
  • Test under load: After repair, perform a supervised test charge while monitoring temperature and smell. Any recurrence requires immediate shutdown and further investigation.
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Repair Difficulty

Professional Required 5/5

Required Part

Main power contactor
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