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80 Amp wall charger potiential fire hazzard?

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The instructions may say to install the cover before operation, but I do not think that there is an interlock. I believe that the HPWC will operate with the cover off.
The installation instructions *tell* you to operate the HPWC with the cover off when you run the self-test after installation - you hang the cover loosely over the unit whilst poking the reset button. I'd charge in that configuration, but still kill the power before lifting the cover and taking thermal data, though.