NHTSA Complaint #10586711 — 2012 FORD FOCUS ELECTRIC

THE PRODUCT IS BOSCH POWER XPRESS 240 VOLT CHARGER COUPLED TO MY 2012 FORD FOCUS ELECTRIC. IT IS SET TO 30 AMPS FOR MY VEHICLE....UPDATED 12/17/14 *BF THIS CHARGER WAS PUT IN SERVICE ON 7/22/2013. I NOTICED IN FEBRUARY THAT THERE WAS A NOTICEABLE ELECTRICAL SMELL OF MELTED PLASTIC AFTER CHARGING THE CAR, BUT THERE WAS NO DAMAGE. I FIGURED THAT WITH THE VERY COLD AIR IN MY GARAGE THAT MY SENSE OF SMELL MAY BE OFF. I CHARGE AT HOME AND AT WORK. THE WORK CHARGER IS MADE BY PEP. I HAVE ALSO OCCASIONALLY USED CHARGEPOINT CHARGERS. DURING THE WINTER I ALSO PRE-CONDITION THE VEHICLE TO 85 DEGREES. ON 3/27/14 I NOTICED FIRSTHAND THE ISSUE WHILE GETTING IN THE CAR IN THE MORNING. THE VEHICLE WAS STILL PRE-CONDITIONING WHEN I UNPLUGGED IT. THE CHARGER WAS MELTED AT THE CHARGING STATION COUPLER END AND THE VEHICLE CHARGE INLET PORT WAS ALSO MELTED. I TOUCHED THE CHARGING STATION COUPLER AFTER UNPLUGGING IT FROM MAIN POWER AND THE TIPS OF THE CONTACTS WERE BASICALLY MOLTEN PLASTIC THAT BURNT THE TIP OF MY FINGER. I DECIDED TO SCHEDULE A WARRANTY REPAIR WITH FORD. ON 3/28/2014 I TOOK THE VEHICLE IN FOR WARRANTY SERVICE WITH FORD MOTOR COMPANY AND THEY REPLACED THE CHARGE PORT UNDER WARRANTY. ON 4/8/2014 I CALLED BOSCH ABOUT THE CHARGER AND THEY OPENED A CASE TO REPLACE THE CHARGER UNDER WARRANTY. THE CLAIM WAS ACCEPTED AND PROCESSED ON 4/11/2014. MY CONCERN IS OF POSSIBLE FIRE OR INJURY FROM AN OVERHEATED AND/OR IMPROPERLY INSULATED CONNECTION BETWEEN THE CHARGING STATION AND THE VEHICLE. *TR UPDATED 9/29/2015*JS