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Some dirt in charging port may increase resistance between surfaces, create more heat and even arc. Ports probably got welded together.

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Every DCFC system has temperature monitoring at the port, as well as voltage monitoring on both sides of the system (port and supply). If that voltage gets too big, it should disconnect/put itself into a fault condition.

If the EA chargers are not doing this, this is a huge safety hazard.

Given the report is a 'large bang', it doesn't seem to me to be a heat-based melting issue. Seems like a sudden short or surge of power.

In my experience, both with Tesla and EA failures, that temperature monitoring at the handle may be the most common failure. Usually manifests as a 100A cap on charging speed.

My guess for the loud bang, based on when these reports first happened, is that it's the pyrofuse blowing. They're not quiet.

If the explanation were that simple, one would expect to see the same problem at all kinds of EV fast chargers, not just EA ones.

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