It shouldn't be hot... Not even warm...I have an 80 amp charger and it's always cool to the touch. Hot is dangerous. Burning smell is dangerous

 

You could have some loose connections at the power terminals in the charger, or at your circuit breaker. I would have an electrician check those connections. Bad connections cause high resistance and everything heats up. Sometimes the screws holding the wires can work themselves loose. I had this happen with a 14-50 receptacle once and it melted down.

 

The thing that’s perplexing though is that there is no heat at all on the charging cable, charging station or breakers. Only right at the vehicle port and charging plug itself.

 

Did you install it yourself? Is it hard wired or are you using a 14-50 receptacle? Either way, the connection at the truck should not be hot at all. I would call the connector manufacturer asap to discuss with them.

If you installed it yourself, what size wire did you use? AZbill is right, the lugs connecting your wires will work loose over time, especially as you put the amount of power we're putting through the system. If you used too high of gauge wire this seems to happen more from what I've seen. Definitely call the manufacturer though, I've had my handle warm, but never hot.

 

Had a licensed electrician install it. And it’s hardwired to 100A. He’s happy to come back out to check the connections, but is convinced that it’s highly unlikely to be the connection or the PowerUp+ unit given that there is no heat anywhere except for right at the truck at the handle and port. Appreciate all the helpful advice from all of you guys and will definitely call the manufacturer as well.

 

2ga THHN would be the minimum I’d use for 80a. I just had to reduce the amperage setting on my dad’s 80amp because I think he gave the electrician insufficiently thick conduit he bought off Amazon. Nothing in the chain should be over 135F to the touch. If everything is sufficiently sized, most of it won’t get above body temp.

 

Try cleaning the pins on the J1772 connector, both on the charger side and the truck side. Get a can of compressed air and blow them out to remove dust, then use a Q-tip with some alcohol to wipe them. Look for any damage or corrosion around those pins also.

 

Well I had all that to happen to me. They said it’s the charger port housing. It’s in the shop now to be replaced. I have had charger door replaced and battery(ies) replaced….. mine had stopped re-charging when rolling as well. I pray this is the last time it’s in shop. I still love it and love driving it. I was a year in in March….. I’m gonna give it more time and pray this is it! 🫣

 

Did the charger port housing replacement fix your issue? Are you using the PowerUp+ also?

I finally got a warranty replacement PowerUp+ charger after contacting the GM EV Concierge several weeks ago. That model charger is apparently on national backorder, which is concerning because I suspect existing units like the replacement one I just received under warranty, may have issues.

That said, I had it installed today and although I’m getting the expected 30 mi/hr charge rate for the majority the charging time, the handle is still getting hotter than it seems it should. The only time it drops below the 30 mi/hr charge rate seems to be when the batteries are getting too hot, I guess, in the 93-degree garage, the cooling fans are going full blast and the speed drops to 24 mi/hr, but once the fans stop, it shoots back up to 30.

Also, I’m intermittently getting the “spear” warning light too! I think at this point I’m going to have to take the truck in to have the charging port housing tested for potential issues maybe, but am skeptical that they will be able to uncover the issue since they won’t be able to replicate it at the shop without the benefit of the PowerUp+ charger charging it. So frustrating and still makes me afraid to charge overnight given the heat.

 

If it’s hitting over 122F (50C) at the plug then something is wrong.

 

Dude - there is this thing called the SUN and it makes black things outside hot