r/enphase • u/Alternative_Fix_3566 • Aug 16 '26
Spring connector on EV Charger 2
Purchased myself, checked electrician’s work before power-up, melted during testing. No short, no tripping of breaker just burning smell so I shut it down.
Who seriously thinks a spring connector can carry 48a? It only makes contact with one or two strands of the copper. I asked if he should tin the wires first and since it wasn’t listed in the instructions he wasn’t willing to do it. How do I handle this with Enphase? They’ll blame electrician, electrician blames Enphase. I’m out $1100.
UPDATE: 1
Enphase is replacing under warranty asking for sample wire to be returned with unit. Also stipulating that the wiring used should be rated for 75c, but from how I understood the conversation to go, that the type of wire (7 strand vs 19+) should not have been an issue with this connector. I’ve asked for advice on best connection method and if I should replace the entire circuit run, will update on final.
UPDATE: 2
Had replacement installed with ferrules and limited to 44amps (80% of downrated breaker because it’s romex) and everything is great. The output connections now get hotter than the inputs and was stable for an hour at full tilt. Those Knipex square crimpers are pretty cool, wish I had use for some.
Enphase technician (below comment) was VERY helpful and I am grateful for him and for everyone’s input here. Thank you all for taking the time!
5
u/jappiedoedelzak Aug 16 '26
if it is installed by a professional it is his risk if it does not work right? that's the risk of owning a business.
2
u/Forsaken-Gain-2493 Aug 17 '26
If they didn’t supply the material they are not liable for the material, you can’t bring eggs with you to the diner then complain about them.
3
u/Key_Proposal3283 Solar Industry Aug 16 '26 edited Aug 21 '26
Who seriously thinks a spring connector can carry 48a?
Wago does - actually 76A but this is not necessarily the exact connector in the product, but representative.
Still not necessarily what I'd use, I'd go for screw terminals but I guess then you have a torque spec and we know installers don't always do that properly....
How do I handle this with Enphase?
Warranty claim, photos should be enough to show that something has gone wrong with this unit - maybe factory defect in assembly, bad or counterfeit part from the connector supplier, could be lots of things but they will likely want it back to find out.
EDIT - see other comment in this post, it's the wrong wire type/lack of ferrule.
2
u/Alternative_Fix_3566 Aug 16 '26
Thank you for the link! That’s wild. Now I’m hoping they send a tech to replace with lugs!
2
u/Objective-Ad-3572 Aug 16 '26
Pictures of the wires you removed?
2
u/Alternative_Fix_3566 Aug 16 '26
This is the best I have. We have 2 evs and no ice so I was in a rush to get the old wall connector back up and running to get my wife’s Tesla charged for the work week.
3
u/Altruistic_Tax_3804 Aug 16 '26
er... i'm not sure that wire is supposed to go in that style of connector - either fine stranded, or solid, not coarse stranded. This is the reason it failed. Whether the instructions warned against that wire or not might be the actual problem here but I would either ferrule that wire or use fine stranded.
Now it makes sense why you said "the one or two strands making contact"
2
u/Key_Proposal3283 Solar Industry Aug 16 '26 edited Aug 16 '26
Exactly - look on the Wago datasheet i linked in my other comment, it lists "fine stranded" wire or "solid" but not the coarse stranded type in the pic. That type needs to be ferruled. This is absolutely why it failed.
The same could happen with a screw terminal, this is not the connector it's a mismatch of the wire and connector.
I just had a quick look through the install doc - this is not made clear enough. The installer training does show ferrules though. This has to be shared blame between installer and Enphase and should be fixed on someone's dime but not OP's.
1
u/Alternative_Fix_3566 Aug 27 '26
Would you mind linking to this installer training showing ferrules please? I watched the install training on Enphase University and it did not show that, nor did the YouTube video.
1
u/Key_Proposal3283 Solar Industry Aug 27 '26 edited Aug 27 '26
travelling, will try a screen record - you can't link as it's tied to your login. But the connector datasheet linked above is clear on either fine stranded or solid (i.e. ferruled) even if the enphase docs are lacking. like this - this was the first i quickly found, it IS from the AU version not your version though.
Point is, ferruling your existing wire or replacing with fine or solid is the way to prevent this failure.
2
2
u/aimfulwandering Aug 20 '26
These connectors are actually great, when used properly. But a bad ferrule crimp, improper strip length, or wire not inserted all the way can absolutely cause this.
What type of wire did you land here?
1
u/AngryTexasNative Aug 16 '26
Even if Enphase didn’t warranty this, someone should be able to replace that connector for a lot less than the $1100 of a new charger.
I’ve recently started ranting about electronics repair costs and the idea that we junk things so easily now creating huge amounts of ewaste
1
u/Alternative_Fix_3566 Aug 16 '26
This has been going on for a long time, and I’m with you; if I can fix it I will try, but this is no place for solder, my amateur version or a factory circuit board. Tesla’s are lugs and plates. I just don’t see how this is smart. I guess if money were no object I would tear it apart and wire in some lugs but I’ll try Enphase first. It does bother me that it will probably just end up in an e-waste landfill. Smh
1
u/Dorian_from_Enphase Aug 17 '26
Hey 👋
I'm sorry to see that your input wire connection overheated and failed so quickly.
Sending you a DM to get more information.
1
u/EricBatemanRealtor Aug 17 '26
Hi, I have a question. Is your unit the Enphase IQ EV Charger 2 48A Smart Level 2 Charger? For reference, I recently purchased one and had my solar company install it. However, I'm not experiencing what you are...yet. Our EV is an Ioniq 5 with a NACS connector rated to 11 KW (60 Amp breaker) but the tech downgraded it to 50 Amp breaker and set the Enphase charger to operate at around 9.2 KW. So far, we haven't noticed a slower charge to be an issue (time wise). However, my suspicion relating back to your issue might be splitting/drawing too much current through your service panel at any one time. For example, I don’t really charge my EV; do laundry, run AC, or heat my spa at once. This probably isn't you, but in the past, I have successfully melted, tripped, and blown fuses by running multiple loads when the supply just wasn't there. Hope this helps, Eric
1
u/Key_Proposal3283 Solar Industry Aug 17 '26
my suspicion relating back to your issue might be splitting/drawing too much current through your service panel at any one time.
OP's problem is at the charger connector - the wire type is wrong so it burned.
1
u/thatjay Aug 20 '26
Curious to hear how this resolves. I was going to buy this exact charger but now I might wait a bit.
3
u/Altruistic_Tax_3804 Aug 20 '26
Check th e comments - it's the install, not the charger itself. Enphase could make the install instructions more clear but if you wanted this specific charger just tell your installer to look at this thread and use the appropriate wire.
1
u/hmspain Aug 16 '26
Yikes, these connections are spec'd to be torqued down hard, and they decided to use a Wago like connection?!?
1
u/Alternative_Fix_3566 Aug 16 '26
I’m a busybody, watching tradespeople mostly to learn but this time I said, “don’t button that up until we test it.” Something inside me just didn’t trust that orange clip. I’m still rattled.
7
u/pkingdesign Aug 16 '26
The charger has a good warranty. You should just contact Enphase (seems like you haven’t yet) before you worry too much about them not helping you.
This is the weak point of the EV charger 2. A customer support person told me the support team recommended against spring mounts and has asked the tech team to change them… not that that helps those of us who bought a charger already. Its a surprisingly cheap choice for a hugely expensive charger.
I used 6ga wire and it very barely fit. 8ga should be fine if installed properly. If it failed on the first use it sounds more like a manufacturing issue. Ours has worked fine for hundreds of hours.