Visible arcing or sparking when plugging in or unplugging the J1772 connector, sometimes accompanied by a popping sound.

Safety first: Arcing can cause burns and fire. Stop using the charger immediately and turn off power at the breaker.

• Inspect connector: With power OFF, examine the J1772 pins for pitting, blackening, or metal transfer. Replace the J1772 charge cable assembly if damage is evident.
• Check contactor operation (power OFF): Test the main power contactor for welded contacts by checking continuity between line and load with the coil unpowered. Replace the main power contactor if welded.
• Verify wiring: Ensure that the output is routed only through the contactor and not directly connected to the line terminals.
• Operational practice: Always stop charging via the app or vehicle (if supported) before unplugging, to minimize load at disconnect.
• Professional inspection: Due to the safety implications, have a qualified technician inspect the entire charger and branch circuit before returning it to service.