Zaptec Overheating Due to Poor Connections or Environment

Charger enclosure becomes unusually hot to the touch during or after charging, even at moderate current

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.

Possible Causes

Loose supply terminals, Undersized wiring, Blocked ventilation, Mounting on heat-retaining surface with no airflow

Safety first: If the enclosure is too hot to touch comfortably, stop using the charger and switch off the breaker.

Steps:

Check installation: Ensure the charger is mounted according to Zaptec clearances and not inside a sealed box.
Reduce current: Temporarily lower the maximum current in the app and monitor temperature.
Technician inspection: Open the unit with power off and check all terminals for tightness and signs of overheating (discolored insulation, melted plastic). Correct wiring and replace any damaged components.

Hard 4/5

Terminal Block / Internal Wiring

Check Price on Amazon

We may earn a commission from links on this page.