Wall charger was tripping my breaker: solution was to tighten the screws for the line out

[davekarow]

A while back my wall charger suddenly started tripping the breaker a few minutes into each charge.

My short term fix was to throw the dip switches so that it went to the second highest charging level instead of full power. That worked, but it was annoying to charge about 10% slower all the time.

== be sure you turn off the power supply before you try what I’m about to explain ==

A day or two ago I finally set the time aside to shut off my breaker open the box and tighten the screws for the line in and the line out.

The screws for the line in from power wouldn’t turn at all; they were still as snug as the day I installed it.

The screws for the line out to the cord were each willing to turn almost exactly a quarter turn.

After I did that flipped it the dip switches back to full power and now I can charge at top speewithout tripping the breaker.

Notice the blue lines in the before and after pictures. I’m guessing the factory marked those. I was grateful they were there, so I could see exactly how much I had tightened it to make them snug.

below are pictures of the before and after for the screws and the dip switches

Sponsored

 

[mcdaniken]

That green wire looks pretty gnarly. If it trips again, Id think about replacing the chewed up part

 

[sac602]

Also tighten the wires leaving the breaker. The high voltage repeatedly cycling can cause a tiny bit of expansion that eventually loosens the connection. Happened to me after a few months. Obviously turn off main before tightening. 20-23 ft-lb torque. Once retorqued, I have not had any repeated issues. I posted on this a while ago.

 

[SwampNut]

That green wire looks pretty gnarly. If it trips again, Id think about replacing the chewed up part

The green wire is not involved in the circuit and the insulation damage is irrelevant.

 

[godfodder0901]

Also tighten the wires leaving the breaker. The high voltage repeatedly cycling can cause a tiny bit of expansion that eventually loosens the connection. Happened to me after a few months. Obviously turn off main before tightening. 20-23 ft-lb torque. Once retorqued, I have not had any repeated issues. I posted on this a while ago.

The specific torque value is printed on each breaker.

Sponsored