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Zappi GLO — EV charging cable stuck in car

Home › Solar Owners Handbook › Zappi Glo Ev Cable Stuck

Cable stuck after charging? Here is what to do

If you cannot remove the Zappi GLO charging cable from your EV's charging port after a session, there is no need to worry. This is usually straightforward to sort out. The cable is physically locked inside the car's charging socket, and in most cases the issue is on the car side, not the Zappi.

This guide walks you through the steps to release the cable, from simple fixes like unlocking the car again, through to the manual mechanical override under the bonnet if needed.

Note

This article covers the tethered Zappi GLO. Tethered means the charging cable is permanently attached to the charger, rather than being a separate cable you plug in yourself. The lock discussed here is inside the car, not on the Zappi. If you have an untethered Zappi (one with a socket, where you use your own cable) and see a Lock Failure ! #23 error on the display, that points to a fault with the locking pin on the charger side and is not covered here.

Why does the car lock the cable?

Under the standard used for home EV charging in Ireland (IEC 62196, Type 2), electric vehicles are required to lock the charging cable in place while charging is active. This is a safety feature. It stops the cable being pulled out accidentally while electricity is flowing.

The car releases its lock when both of the following are satisfied:

The charging session has properly ended

The Zappi and the car have finished talking to each other, and both agree the session is over.

The car has been unlocked by the driver

The car must be unlocked. The locking pin in the charging port only releases when the car is unlocked.

If either condition is not met (for example, if the car's software still thinks a charge is in progress, or if the two never finished talking to each other), the car will keep the cable locked. The Zappi may have gone to sleep or timed out before the car had a chance to end the session properly. This can also explain why some cars refuse to lock or shut down after an interrupted charge.

Step 1: Stop charging from the car's touchscreen

Use the car's own charging controls, not the Zappi app, to stop the session. The car is in charge of the conversation between the two, so ending the session from the car side sends the clearest possible signal to release the lock.

Tip

This is the most reliable first step. If the car stops the session cleanly, the cable lock should release within a few seconds.

Step 2: Unlock the car using the key fob

On many EVs, the charging port solenoid lock is tied to the door lock state. Press the Unlock button on the key fob. On some models (Hyundai, Kia, VW ID series, and others), pressing Unlock twice in succession sends a specific signal to release the charging port lock separately from the doors.

Wait 5–10 seconds after pressing before attempting to pull the cable.

Step 3: The push-then-pull technique

If the cable has been yanked against the car's lock pin, the pin can become mechanically jammed. In this case:

  1. Push the charging handle firmly into the car's socket to relieve the tension on the pin.
  2. While holding it pushed in, press Unlock on the key fob.
  3. Then pull the cable out with a smooth, steady motion.

Step 4: Try stopping the session via the myenergi app

If Steps 1–3 have not worked, open the myenergi app and attempt to stop the charging session from there. In some cases, the app can send a signal that resets the handshake state and prompts the car to release the lock.

Step 5: Restart the Zappi

If you can reach the Zappi's power supply, switching it off and back on at the consumer unit (the fuse board) can sometimes reset the signal the charger sends to the car, prompting it to re-check whether it is still locked. Once the Zappi has restarted, try unlocking the car again.

Last resort — manual cable release under the bonnet

Caution

Always stop the charging session first (from the car's screen, the myenergi app, or by restarting the Zappi) before pulling the mechanical release. Forcing the lock open while electricity is still flowing can cause an electrical spark or damage the locking pin.

If none of the above steps work, most cars have a mechanical override for the charging port lock, reached from under the bonnet. It is a physical cable or lever that pulls the locking pin back directly, bypassing the car's software altogether.

Important

Using the manual release does not fix the underlying communication issue; the car's software may still be stuck in a “charging” state. After releasing the cable:

  • Turn the car off and back on. This means a full power cycle, not just waking the screen.
  • Wait until the charging port light or indicator returns to its normal (non-charging) state before plugging in again.

Refer to your specific vehicle's handbook for the exact location of the manual release. It is typically a small loop or tab on the plastic trunking inside the front bonnet void, near the charging port.

Preventing the issue — correct departure sequence

Order of operations matters. Follow this sequence every time you finish charging to avoid the cable becoming stuck:

  1. Stop the charging session, either via the car's infotainment screen or the myenergi app.
  2. Wait for the Zappi to show EV Connected (not charging), or for the car's port light to stop showing that it is charging.
  3. Unlock the car using the key fob.
  4. Remove the cable promptly; most EVs will relock the port after 15–30 seconds if no cable removal is detected.
  5. Only then get in the car, start it, or change settings.
Important

The most common cause of this issue is pulling the cable before the session has fully ended, or waiting too long after unlocking the car (the port relocks automatically).

myenergi app — Lock Function settings

The myenergi app has a Lock Function setting under the Zappi device settings. This controls the locking pin on the Zappi's own socket, so it only matters on untethered Zappi models (ones where you use your own cable). The Zappi GLO is a tethered unit, so these settings do not affect the lock inside the car described in this article.

However, if you also have an older untethered Zappi on site, confirm the Lock Function is set correctly:

EV Unplugged

Should be OFF. Do not lock when no cable is connected.

Charge

Should be ON. Lock when actively charging.

Auto Hide

Should be OFF.

Firmware

If this keeps happening, check that the Zappi GLO has the latest software (myenergi calls it firmware) via the myenergi app. If the software on the charger and the software managing charging in your car do not match up, the two can keep failing to end the session cleanly.

Need a hand?

If the cable will not release, or you run into any issues during the steps above, please get in touch with your installation team at PureVolt Solar and we will be happy to help.

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