NHTSA Complaint #11432086 — 2017 CHEVROLET BOLT EV

I stopped for a DC fast charge at an Electrify America station to ensure that my vehicle's battery level would stay over "70 miles of charge" to reduce fire risk (per GM recommendation). The vehicle has been programmed to remain at or below a 90% charge limit. After charging for 25 minutes, I unplugged the CCS1 connector from the Bolt by pressing the connector release button and pulling gently. To my surprise, the connector unlatched and disconnected immediately while charging at roughly 35,000 watts (>80 amps, 400 volts) and both the connector and my car's charging port began emitting a strong sulfur odor. The connector is supposed to have a high-voltage safety interlock that prevents either side from being moved while current is flowing. I have seen this interlock technology on many different chargers (CCS, CHAdeMO, Tesla) and have never seen it fail. After the incident, I inspected and photographed the charging port and charging station connector and found both sides seriously burned, melted and damaged. The connectors suffered oxidation, discoloration, and other metallic contamination/damage. The vehicle's inlet port contacts are blue/orange/black, not silver, and sections of metal appear to be melted away. The charger side connector contacts are discolored and have similar erosive/melting damage. The damage appears to be identical to arc flash plasma erosion. Prior to this incident, I regularly inspected the DC fast charge port and found it to be in good condition with a functioning seal, orange cover flap, clean silver pins and no damage. Before plugging in, I had inspected the charge station connector and could not see anything wrong with it. The charge connector serial number was entirely worn off. At this point, I do not feel comfortable fast charging my Bolt EV out of concern that the inlet port may overheat and catch fire. The inlet port needs to be replaced and the charging station connector needs to be replaced (and the interlock issue resolved).