The charger was returned on april 6, 2016 via (b)(4).Prism investigation: when the charger was plugged in, the led became green.When the charger was plugged into a demo unit, it would or would not transmit power based on how the connector was oriented.When the connector was twisted, the charger would make a "pop" sound; during this movement, the charger led would change from off - green - red.The voltage measured approximately 26 v, but was variable dependent on how the connector was oriented.Root cause: this connector design passed pull testing, the effect of gravity from the weight of the charger's body, puts perpendicular stress on the connector over time.Corrective action: the charger was replaced for customer.An external heat shrink tube with adhesive was added around the connection point, through ecr 1052, released on august 26, 2016.This tube will be added to all p440 chargers going forward.
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