Why Does Your EV Stop Charging Suddenly? Let’s Troubleshoot!

Charging interruptions (aka "charging stops") are common for EVs, often caused by safety mechanisms or equipment issues. Here’s a step-by-step guide to figure out what’s going on:

1. Quick Checks (5-Minute Fixes)

1. Check the Connection
   ✅ What to Do:

Unplug the charger → Check for dirt, water, or burn marks on the plug or car port

Reinsert the plug and listen for a "click" (means it’s locked in place)

Try another charger to rule out a faulty station

⚠️ Watch Out For:

Plug temperature > 65°C (may trigger safety cut-off)

Cable bent > 90° (can damage internal wires)

2. Charger Status Lights

2. Environmental Factors

1. Overheating (Common in Summer)
• Triggers:
• Charger internal temp > 50°C
• Battery temp > 45°C (BMS limits power)
• Fix:
• Charge during cooler hours (early morning/night)
• Use liquid-cooled chargers (e.g., Tesla V3)
2. Cold Weather (Winter in Northern Regions)
• Symptom: Charging power drops below 3kW
• Fix:
• Preheat the battery (start charging before driving)
• Use EVs with battery heating (e.g., BYD Blade Battery)

3. Car Settings & BMS Limits

1. SOC Limits
• Default Logic:
• Fast chargers: Power drops sharply after 80% (to protect battery life)
• Slow chargers: Can charge to 100%, but the last 10% takes forever
• Custom Settings:
• Tesla: Adjust charging limit on the touchscreen
• NIO: Set charging limit in the app
2. Battery Balancing
• Symptom: Charging stops at 95% repeatedly
• Reason: BMS is balancing cell voltages
• Fix: Keep the charger plugged in until complete (usually 1-2 hours)

4. Hardware Issues

1. Car-Side Problems
• Symptoms:
• Can’t charge at any station
• Dashboard shows "Charging System Fault"
• Fix:
• Restart the car (disconnect 12V battery for 30 seconds)
• Visit a service center to check OBC (On-Board Charger) or relays
2. Charger-Side Problems

Who’s Responsible:

5. Collect Evidence & Get Help

1. Key Evidence:
• Take a photo of the charger error code (e.g., "CP Signal Error")
• Export charging logs (Tesla users can use Service Mode)
2. Complaint Channels:
• Operator hotline (State Grid: 95598)
• Consumer protection (National 12315 Platform)

Quick Troubleshooting Flow:
Check connection → Rule out environmental factors → Confirm SOC settings → Identify car/charger issue → Collect evidence

With these tips, you can solve 90% of charging interruptions. If the problem persists, use diagnostic tools (e.g., OBD-II to read BMS data) for deeper analysis.