Why Is My EV Charger So Hot? Causes and Fixes

If you’ve ever noticed your EV charger or charging cable feeling hot to the touch, you might be wondering: Is this normal—or is something wrong?

A warm EV charger is common, but excessive heat can signal a problem that reduces efficiency or even creates a fire hazard. In this guide, we’ll cover why your EV charger gets hot, when it’s a concern, and what you can do to fix it.

Is It Normal for an EV Charger to Get Warm?

Yes—some heat is perfectly normal. EV chargers work by pulling a lot of electricity over a sustained period of time, and any electrical device under load will generate heat.

However, your charger or cable should never be too hot to comfortably touch. If it is, there’s likely an issue that needs attention.

Common Causes of a Hot EV Charger

1. Loose or Poor Connections

• A plug that isn’t seated fully or a worn outlet can create resistance, which generates heat.

• Fix: Ensure the plug is fully inserted and inspect outlets for signs of wear, discoloration, or damage.

2. Undersized Wiring

• If your EVSE is installed on wiring that’s too small for the load, the wires can overheat.

• Fix: Always install chargers on the proper gauge wire for the amperage. A licensed electrician can confirm this.

3. High Ambient Temperatures

• Charging in a hot garage, direct sun, or poorly ventilated space can raise cable temps.

• Fix: Improve ventilation or relocate the charger to a cooler spot if possible.

4. Long Charging Sessions

• Level 1 charging (110V) can run for 12+ hours, which builds up heat in cables.

• Fix: Consider upgrading to a Level 2 charger (240V), which reduces charging time and heat buildup.

5. Coiled or Covered Cables

• Heat can’t escape if the cable is coiled tightly or covered by rugs or objects.

• Fix: Lay cables out flat and keep them uncovered during charging.

6. Defective or Low-Quality Charger

• Some off-brand or older chargers lack proper safety protections, making overheating more likely.

• Fix: Invest in a UL-certified Level 2 charger from a reputable manufacturer.

7. Breaker or Circuit Issues

• If your breaker or electrical panel is undersized, it may not handle the continuous EV load, creating heat in the circuit.

• Fix: Have an electrician check your breaker capacity and wiring.

Warning Signs of Dangerous Overheating

You should stop charging immediately and investigate if you notice:

• The charger or plug is too hot to touch

• Melted or discolored plastic around the plug or outlet

• Burning smell from the charger or outlet

• Breaker trips frequently during charging

These are signs of a potentially hazardous condition that needs professional attention.

How to Prevent Your EV Charger From Overheating

• Install on a dedicated 240V circuit with correct wiring size

• Use only certified, brand-name chargers

• Keep charging cables straight and ventilated

• Avoid running chargers in direct sunlight or hot garages

• Have your electrical system inspected by a licensed electrician if overheating continues

Final Thoughts

It’s normal for an EV charger to get warm, but it should never be uncomfortably hot. Overheating can be caused by loose connections, undersized wiring, or faulty equipment—and it’s not something to ignore.

If your EV charger is running hot, upgrading your setup with a properly installed Level 2 charger is the safest long-term solution.

At Frisco EV Charger Installation, we specialize in installing reliable, code-compliant home charging stations that run cool, safe, and efficient.

👉 If you need help with EV charger installation in Dallas, Plano or the surrounding area, contact us today for a free consultation and enjoy peace of mind every time you plug in.