NHTSA Complaint #11666452 — 2022 PORSCHE TAYCAN

Session ID: [XXX] EA Case No: [XXX] Time of incident: [XXX] While DC fast charging my 2022 Porsche Taycan at an Electrify America station, I experienced a critical malfunction during cable disconnection. Upon unplugging, there was a visible spark, fire, and smoke on the car's charging port. The DC charge port showed heat damage, with melted pins that rendered it unusable. A Porsche dealer confirmed the damage likely resulted from the charging event, not a vehicle defect. A repair invoice of ~$5000 has been issued. This incident posed a serious fire and electric shock hazard. If someone had been closer to the port, injury or fire could have occurred. No warnings or errors were displayed by the vehicle before or during the event, which happened suddenly and without shutdown or alert. The dealership inspected the damage and noted signs of thermal/electrical malfunction. A copy of the dealer's report is attached with this form. The component has not yet been examined by Porsche North America, insurance, or third parties, but I am escalating the issue. The damaged charger remains nonfunctional as of June 11, and Electrify America has stated the charger's connector pins need replacement. Electrify America has also refused to reimburse any damage fees to me. A picture of the out of operation charger as of 6/7 is attached. The vehicle charge port is available for inspection if needed. I can't confirm whether the malfunction was caused by Electrify America’s charger, the Taycan’s port, or both, however evidence suggests the HV charging cable triggered the fault. This event presents a credible safety risk to people and vehicles. EA's chargers are widely used, and if this issue affects compatibility with vehicles like the Taycan, other users may be at risk of fire or shock. No injury occurred, but the potential was significant. I am reporting this to NHTSA to urge investigation into the broader safety implications. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)