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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, do not panic; this is usually straightforward to resolve. 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, where the cable is permanently attached to the charger. The lock discussed here is inside the car, not on the Zappi. If you have an untethered (socketed) Zappi and see a Lock Failure ! #23 error on the display, that relates to a separate solenoid issue on the charger side and is not covered here.

Why does the car lock the cable?

Per the IEC 62196 (Type 2) charging standard, electric vehicles are required to lock the charging cable in place while a session is active. This is a safety feature: it prevents accidental disconnection while high-voltage AC is flowing.

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

  • The charging session has properly ended, both the Zappi and the car have completed the handshake to signal “session over”.
  • The car has been unlocked by the driver.

If either condition is not met (for example, if the car's software still believes a charge is in progress, or there was an incomplete handshake), the car will keep the cable locked. The Zappi may have entered a sleep or timeout state before the car had a chance to cleanly end the session, which can also explain why some EVs refuse to lock or power down after an interrupted charge.

Step 1: Stop charging via the car's infotainment screen

Use the car's own charging controls (not the Zappi app) to explicitly stop the session. The car is the “master” in the charging handshake, 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: Power-cycle the Zappi

If the Zappi is accessible, turning it off and on at the consumer unit can sometimes reset the Control Pilot signal and prompt the car to re-evaluate its lock state. After the Zappi comes back up, try unlocking the car again.

Last resort — manual cable release under the bonnet

Caution

Always stop the charging session first (via the car's screen, the myenergi app, or by power-cycling the Zappi) before pulling the mechanical release. Forcing the lock open while high-voltage current is active can cause an electrical arc or damage the locking pin mechanism.

If none of the above steps work, most EVs have a mechanical override for the charging port lock, accessible from under the bonnet. This is a physical cable or lever that directly retracts the solenoid pin regardless of the car's software state.

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 — 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 display EV Connected (not charging) or for the car's port light to change from charging to idle.
  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 configuration under the Zappi device settings. This controls the locking behaviour of the Zappi's own solenoid at the charger socket; it is only relevant for untethered (socketed) Zappi models. The Zappi GLO is a tethered unit, so these settings do not affect the EV-side lock described in this article.

However, if you also have an older untethered Zappi on site, confirm the Lock Function is configured 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 you experience this issue repeatedly, check that the Zappi GLO firmware is up to date via the myenergi app. Firmware mismatches between the charger and the car's charging management software can cause persistent handshake timing issues.

Still having trouble?

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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