Sun Country Highway
Short Circuit or Overcurrent on Output
Breaker trips immediately or shortly after starting a charge session.
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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
Shorted J1772 cable conductors, Water intrusion causing line-to-ground fault, Loose or improperly torqued lugs at contactor or terminal block, Oversized current setting relative to breaker size
How to Fix / Troubleshooting
Safety first: Do not repeatedly reset a tripping breaker. Turn off power and investigate.
- Visual cable inspection: Examine the entire Sun Country Highway output cable for cuts, crushed sections, or melted spots. Replace the cable if any damage is found.
- Check for water ingress: Inspect the J1772 handle and cable gland for signs of water. Dry thoroughly and correct any failed seals or gaskets.
- Inspect internal connections: With power off, tighten all line and load lugs at the input terminal block and main contactor. Look for burn marks or melted insulation.
- Verify current setting: Ensure the EVSE’s maximum current setting does not exceed the breaker rating. If it does, reduce the setting or upgrade the circuit per code.
- Insulation testing (advanced): A technician can perform a megger test on the output cable to confirm insulation integrity. Replace the cable if insulation resistance is low.
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Repair Difficulty
Hard
4/5
Required Part
J1772 Output Cable and Handle Assembly
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