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The credentials JSON must be base64-encoded exactly once into the Kubernetes secret, with no trailing newline. Two common mistakes cause this error: mounting the raw 1password-credentials.json as text without encoding it at all, and double-encoding it. Also note that GNU base64 wraps lines by default, so encode with base64 -w 0 (or strip the newline), a wrapped value triggers "illegal base64 data at input byte 1474". Multiple users confirmed fixing the encoding resolved the connect-sync startup failure.
Source: https://github.com/1Password/connect-helm-charts/issues/17