Zaptec Thermal Derating or Marginal Supply Voltage

Charging starts but stops after a few minutes without any visible error on the charger; vehicle shows ‘charging interrupted’

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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

Charger overheating due to poor ventilation, Undersized supply cable causing voltage drop, Loose terminals heating under load, Ambient temperature above specification

How to Fix / Troubleshooting

Safety first: If the charger housing feels very hot to the touch, stop using it until inspected.

Steps:

  • Check surroundings: Ensure the charger is not enclosed in a small cabinet or covered by objects.
  • Reduce current: Use the Zaptec app to lower the maximum charging current and see if the session becomes stable.
  • Time-of-day test: Try charging during cooler hours (night) to see if the issue is temperature-related.
  • Technician inspection: Check supply cable size, terminal tightness, and internal temperature logs (if available). Replace any heat-damaged components.
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Repair Difficulty

Medium 3/5

Required Part

Internal Temperature Sensor / Terminals
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