[jhautz]

I had one that was like an arc welder when I went to plug it in the first time. After a few attempts of plugging and unplugging the arcing got less and less and eventually went away and the normal capacitor "spark" is all I got. I called CC and they told me that it was some sort of short (my suspision was a dead short across the heat sink on the +/- 6.5mm sockets.) It worked fine after it stopped arcing when I plugged it in. I'm not sure if what you are seeing is the same thing, but what I had happen certainly wasnt "normal" CC replaced it for me. After they got the return unit they called me to ask what was wrong and that the controller was testing fine. I then re-told the repair department what had hapened and they looked closer and told me they could see that there had been a problem. I didn't get into the details as I already had a replacement back from them, installed in my truggy and running fine.