Browse Wiki

Thermal Fault Or Charger Overheating

Use this path when charging slows or stops because the charger is overheating or showing a thermal fault.

Before escalating, use the universal reset once: disconnect AC power for 30 seconds, confirm the LEDs are fully off, then reconnect.

Quick Pre-Checks

Run these quick checks before you assume the charger has a deeper hardware fault.

AC socket is energised. Test it with another appliance.

AC plug is fully inserted, undamaged, and its pins are clean and straight.

DC output connector is fully locked into the vehicle inlet, not just inserted.

Both AC and DC cables are free of cuts, kinks, crushing damage, or severe bending.

Charger vents are unobstructed and have at least 10 cm clearance on all sides.

Ambient temperature is below 45 C.

No extension cord is being used, or the cord is correctly rated and within the allowed length.

Universal reset has been tried: AC off for 30 seconds, then reconnect.

Step-by-Step Field Checks

Follow the steps in order. Stop and escalate as soon as a step says the issue is not field-serviceable.

1

Separate derating from a true thermal fault

Flashing current bars usually mean the charger is derating because of temperature, not failing. A true thermal fault is a fault code such as F06, F07, or F08.

Flashing bars = derating | fault code = thermal trip
2

Cool the charger before retrying

Disconnect AC immediately and allow at least 20 minutes for the charger to cool before the next attempt.

AC off -> cool for 20 min
3

Clean all vents and fins

Use a dry cloth, dry brush, or gentle compressed air. Dust build-up is one of the biggest reasons repeated thermal faults keep returning.

Dry clean vents every 3 to 6 months
4

Restore airflow around the charger

Keep at least 10 cm of clear space on all sides and above the charger. Never cover it with fabric, documents, or packaging.

Minimum 10 cm clearance
5

Check ambient conditions

Above 45 C ambient, output current reduces. Charging in direct sun, inside a hot compartment, or near other hot equipment can force derating or shutdown.

Move to shade or a better ventilated area
6

Repeated thermal fault in good conditions

If thermal trips continue after cleaning, cooling, and restoring airflow, the internal thermal sensor or calibration may have drifted.

Contact service for thermal sensor or calibration checks
If the charger shows a fault pattern at any point, cross-check the LED sequence on the LED Fault Codes page before retrying power cycles.