Charger shows E04 and will not start; sometimes accompanied by a clicking sound from inside the unit.

Safety first: Turn OFF the breaker and verify absence of voltage with a meter if you are qualified. Do not attempt to pry or tap the contactor while energized.

• Step 1 – Power cycle: Turn the breaker OFF for 5 minutes, then ON. Listen for a single clean click when starting a charge. Multiple rapid clicks or no click at all indicate contactor issues.
• Step 2 – Visual inspection (cover removed): With power OFF, remove the front cover. Locate the "Electrify Home" output contactor (typically a block with heavy gauge wires). Check for discoloration, burn marks, or melted plastic.
• Step 3 – Check wiring tightness: Ensure all lugs on the contactor are tight. Loose connections can cause arcing and welding of contacts.
• Step 4 – Manual movement test (if design allows): Some contactors have a visible armature. With power OFF, gently press to see if it moves freely. If it is stuck, the contactor must be replaced.
• Step 5 – Replace if welded: If there are signs of welding or burning, do not reuse the contactor. Replacement should be performed by a qualified technician due to high current and code requirements.