A properly installed EV charger should last years, but many fail earlier than expected. What causes these premature failures, and how can you prevent them? Below are the five most common reasons for EV charger failure and the steps to avoid them.
1. Improper Installation
Common Issues:
- Incorrect wiring leading to electrical shorts or fires.
- Inadequate power supply causing frequent breaker trips.
- Non-compliance with safety codes voiding warranties.
How to Prevent It:
✔ Hire a licensed electrician experienced in EV charger installation.
✔ Ensure your electrical panel can handle the charger's power demand.
✔ Follow manufacturer guidelines and local electrical codes.
2. Environmental Exposure
Common Issues:
- Extreme temperatures damaging internal components.
- Moisture and humidity corroding electrical parts.
- Debris accumulation interfering with ventilation and cooling.
How to Prevent It:
✔ Use a weatherproof EV charger rated for outdoor use.
✔ Install chargers under cover or in enclosed spaces to prevent water damage.
✔ Regularly inspect and clean charging connectors to prevent corrosion.
3. Hardware Malfunctions
Common Issues:
- Overheating of circuit boards and power modules due to prolonged use.
- Voltage fluctuations causing damage to internal components.
- Substandard chargers failing due to poor manufacturing quality.
How to Prevent It:
✔ Invest in high-quality chargers from reputable manufacturers.
✔ Install surge protectors to prevent damage from power spikes.
✔ Perform regular diagnostic checks to detect early signs of wear.
4. Software and Connectivity Failures
Common Issues:
- Outdated firmware leading to charging interruptions.
- Unstable internet connectivity affecting smart charger functions.
- Unresponsive user interfaces due to software bugs.
How to Prevent It:
✔ Enable automatic firmware updates or check for updates manually.
✔ Ensure stable internet or cellular connectivity for smart chargers.
✔ Reset the charger periodically to clear minor software glitches.
5. Lack of Maintenance and Physical Damage
Common Issues:
- Frayed or damaged cables affecting charging performance.
- Dirt and debris buildup reducing charger efficiency.
- Loose internal connections leading to inconsistent power supply.
How to Prevent It:
✔ Inspect and replace worn-out charging cables as needed.
✔ Schedule routine maintenance checks to identify potential issues early.
✔ Keep the charger area clean and free of dust or debris.
Key Takeaways: How to Prevent EV Charger Failures
| Common Issue | Preventive Measures |
|---|---|
| Improper installation | Hire professionals, follow manufacturer guidelines |
| Environmental exposure | Install in a protected area, use weatherproof chargers |
| Hardware malfunctions | Invest in high-quality units, install surge protectors |
| Software/connectivity issues | Enable updates, ensure strong network signals |
| Lack of maintenance | Perform regular inspections, replace damaged cables |
Final Thoughts
EV chargers can last for years when properly installed and maintained. Avoid premature failure by:
- Ensuring correct installation by a certified professional.
- Protecting chargers from harsh weather conditions.
- Using quality equipment with built-in surge protection.
- Keeping software up to date for optimal performance.
- Performing regular maintenance to detect and fix issues early.
Looking for Reliable EV Chargers?
At SANKE, we provide high-performance Level 2 and DC fast chargers built for long-term durability. Our chargers offer cost-effective solutions without compromising quality.
Contact us today to find the best EV charging solution for your needs.
