NeoCharge NeoCharge Smart Splitter 240V

SaferProducts.gov consumer incident report 20251201-B2AA6-2147326002. Severity: Incident, No Injury. Product: NeoCharge NeoCharge Smart Splitter 240V (The product is a NeoCharge Smart Splitter 240V. It is a compact white electrical device designed to share a single 240V outlet between an electric vehicle charger and a household appliance such as an electric dryer. The unit has two 240V receptacle ports on the front and a single 240V plug on the back. It is rectangular with rounded edges and is roughly the size of a small brick, about 13 cm by 13 cm by 7 cm. The exterior casing is hard plastic. The device is meant to automatically switch between loads so only one appliance runs at a time. It is marketed as a safe way to avoid installing a second 240V circuit. The surface labeling includes the NeoCharge brand name and basic electrical information.). Incident: We began using the NeoCharge Smart Splitter exactly as instructed in their safety guidelines and through direct contact by email. The unit was installed correctly. Our EV draws about 22 amps during normal operation which is well below their recommended 24 amps. We never exceeded the load limits stated in their documentation. This is the 2nd unit they've replaced as the first just stopped working. After some routine use, we noticed a light burning smell coming from the unit. This was unusual because the previous replacement unit had been working normally before this. When we inspected the device, we observed clear signs of overheating at 145F and climbing on the outer shell casing. The exterior of the box felt hotter than expected and the plug area began melting. The smell continued each time the EV was charging. We verified that the EV charger, the outlet, and the surrounding setup were all functioning normally and had no issues. There were no visible problems with the outlet or wiring. The only source of heat or smell was the Smart Splitter itself. We searched online and found multiple reports from other custome