How to repair EV charger? Common issues and troubleshooting steps

As electric vehicles gain traction worldwide, homeowners eagerly install EV chargers to keep their cars ready to roll. Yet, just like any electrical device, these chargers demand proper maintenance for sustained safety and efficiency. At SunnyWell we share valuable tips on the do’s and don’ts of keeping your EV charger in top-notch condition and how to repair EV charger by yourself. Charging electric cars can be a puzzle for many. The learning curve, whether using a public charging stations or setting up a home charging system, can be steep. We’re here to empower you with the essential knowledge to troubleshoot typical home charging issues and ensure your EV stays fully charged and ready for the road.

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  • Understand your EV charging configuration before troubleshooting. Such as breaker size and/or charger power output
  • Verify the power supply: Confirm the outlet or breaker is functional and no power outage is occurring nearby.
  • Examine EV charging cable, and charging station for issues. Check the charger screen or LED for fault indicators.
  • Ensure the station is online if networked with the latest firmware.
  • Home EV charger installation

    Troubleshooting Tips to Repaire Your EV Charger

    Step 1. Check your setup

    Firstly, it’s crucial to identify signs of malfunction in the EV charger’s behaviour, whether slow charging or a complete lack of charging. Before fixing the EV station, examine the charger’s overall setup. Confirm if the breaker is sized according to the charger output. Look out for indicators such as the charger being off with no clear indication of being turned on, a tripped breaker during charging, or the charger is ON but displaying a fault error like a ground fault. If you see any of these symptoms, the issue likely lies on the electrical side.

    Troubleshooting steps

    Take voltage measurements between the hot legs or Neutral. In North America, it is expected to observe 240V between L1 and L2 (the hot wires) and 230V between L1 and N (Hot and Neutral) in Europe and the rest of the world. If the breaker consistently trips while charging, most likely it needs a replacement such as below.

    Step 2. Inspect charging cable

    Suppose you connect the charging cable to the electric vehicle while the station is powered on, and charging fails to commence or halts immediately after initiation. Most likely, the charging cable is malfunctioning. In such cases, the EV charger and the vehicle cannot establish the necessary communication for the charging process to initiate in the first place. If you are experiencing these symptoms, follow the troubleshooting step below.

    EV charger repairing steps

    To repair EV charger, first, use a digital multimeter to test for continuity in the pilot wires, which are located on the connector. Don’t worry about the cable brand; all J1772 cable cords support the same communication protocol, ensuring seamless interaction between the charging station and electric cars.

    20ft EV replacement cable

    EV Replacement cable kit

    for Electric Vehicle Charging Stations

    Compatible with most j1772 level 2 chargers (excluding Tesla), a 20-ft cable kit.

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    When connecting the power wires, ensure they are inserted into the charger terminal block correctly. Hot wires and ground or neutral (depending on your region) should be placed in their respective terminal connections. As for the communication wire, typically orange and the thinnest, should be attached to the communication port on the charger, usually labeled as “CP” for the Control Pilot line. This vital wire is the communication channel between the vehicle’s on-board charger (OBC) and the Electric Vehicle Service Equipment (EVSE), relaying crucial information about the charging system state.

    25ft EV replacement cable

    Replacement cable

    for Electric Vehicle Charging Stations

    Compatible with most level 2 chargers (excluding Tesla), this product offers durability, weather resistance, and versatility for various North American electric vehicles. It comes with a 12-month warranty.

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    Step 3. Update firmware if the charger is connected to WiFi

    Certain chargers rely on an internet connection for proper functioning, especially for charging session authorization. Home EV chargers, often labeled as “dumb” chargers, operate in a simple plug-and-charge mode. However, for chargers with a mobile app feature, it’s important to regularly update the firmware and keep an eye on the app for any fault authorizations.

    How to repair OCPP EV charger

    If you reside in a condo or apartment with an EV station installed at your parking stall, chances are high that the unit is OCPP compliant and managed by an EV chargers network. Repairing an OCPP charger in such a scenario demands advanced networking and system knowledge, typically beyond the expertise of the average EV owner. While we’d like to guide you through simple troubleshooting steps, the issue’s root cause may span from hardware glitches to backend networking communication. At SunnyWell, we offer an affordable repair and service package to alleviate your concerns. Don’t hesitate to contact us and we’ll ensure your station is running smoothly.

    Step 4. Fixing slow charging speed

    Charging times for electric cars don’t always align with expectations, and the actual power output of a charging station may not consistently match the advertised maximum. Although this discrepancy can be frustrating, there are some reasons why your electric car charging time may be slower than anticipated. Here are several common reasons accountable for slow charging speeds:

  • One common factor is the limitation imposed by the car’s onboard charger size. Electric vehicles are equipped with an onboard charger that converts grid AC current into DC current for charging the batteries. Typically, most electric cars can handle approximately 7.6kW of AC power, equivalent to a 32A charger. If, for instance, you pair a 48A charger with an EV with a 7.6kW onboard charger, the charging speed will go down due to the car’s maximum power intake.

  • Certain chargers intentionally limit the current output as a safety precaution, referred to as a fallback current. If your charger is equipped with a pre-configured load balancing setting, it’s likely contributing to a lower current output. Contact us, and we can assist in identifying and adjusting the fallback parameter as necessary.

  • Final verdict

    Quick and effective repairs are key when your Electric Vehicle (EV) charger acts up. Whether it’s a wonky connector, a power hiccup, or a software glitch, knowing how to fix it ensures smooth charging for your EV. Additionally, we will keep updating this article with new tricks and handy solutions to repair your EV charger, ensuring that your electric vehicle charging experience remains hassle-free. Stay informed about EV charger repairs to keep your charging game strong!


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