Shell Recharge Overheating Enclosure / Thermal Stress

Charger’s enclosure feels excessively hot to the touch during or after charging, even at moderate ambient temperatures.

Advertisements

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.

Advertisements

Possible Causes

Undersized supply cable, Loose terminal connections, Blocked ventilation around charger, Degraded internal thermal interface materials

How to Fix / Troubleshooting

Fire risk: Excessive heat can lead to insulation failure. Address promptly.

  • Step 1 – Reduce current: In the Shell Recharge app, lower the maximum charging current (e.g., from 32 A to 16 A) and observe if temperature improves.
  • Step 2 – Improve airflow: Ensure the charger is not covered or enclosed in a tight cabinet. Provide at least the clearance recommended in the manual.
  • Step 3 – Check for direct sun: If installed outdoors, consider shading the unit from direct midday sun.
  • Step 4 – Electrician check: Have a qualified technician open the unit (with power off) and inspect terminals, contactor, and internal wiring for discoloration or melting. Retighten or replace as needed.
  • Step 5 – If overheating persists: Internal components such as the contactor or power supply may be degraded and should be replaced.
Advertisements

Repair Difficulty

Hard 4/5

Required Part

Terminal Block and Internal Wiring Harness
Check Price on Amazon

We may earn a commission from links on this page.

Advertisements