Zencar
Intermittent Charging / Dropouts
Charger intermittently stops charging and then resumes on its own; no error code is stored.
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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 internal wiring, Marginal pilot signal connection, Vibration-sensitive fault in relay or contactor, Fluctuating supply voltage within tolerance
How to Fix / Troubleshooting
Safety first: Intermittent faults can be hard to trace. Always de-energize before tightening connections.
- Check supply stability: Have an electrician verify that the supply voltage does not sag excessively when large loads (AC, ovens) start.
- Tighten all terminals: With power OFF, tighten all screw terminals on input, output, and control wiring inside the Zencar charger.
- Inspect pilot and proximity connections: Ensure the small-gauge pilot and proximity wires are secure at both the connector and main control PCB.
- Wiggle test: With power OFF, gently move the output charging cable assembly and internal harnesses while checking for loose connections or intermittent continuity.
- If issue persists: The main control PCB or contactor may have an internal intermittent fault and should be replaced.
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Repair Difficulty
Hard
4/5
Required Part
Main Control PCB
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