Sun Country Highway
Excessive Internal Heating / Poor Thermal Contact
Charger enclosure becomes very hot to the touch during normal charging, even in mild ambient temperatures.
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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 high-current lugs causing resistive heating, Undersized branch circuit wiring, Failing contactor with high contact resistance, Blocked ventilation or installation in confined space
How to Fix / Troubleshooting
Safety first: Turn off power and allow the unit to cool before opening.
- Check installation: Ensure the charger is not installed in a sealed cabinet or too close to other heat sources.
- Inspect and retorque lugs: With power off, tighten all line and load connections at the terminal block and contactor to manufacturer torque specs.
- Look for discoloration: Any brown or darkened insulation near terminals indicates overheating; replace affected components.
- Reduce current setting: Temporarily lower the EVSE’s maximum current setting and observe if heating is reduced. If so, investigate branch circuit sizing and length.
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Repair Difficulty
Medium
3/5
Required Part
Input Terminal Block
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