DCFC melted / welded to Mach-E charge port during charging session (updated with photos) 😱

Logal727 · Nov 25, 2022

This is crazy (reposted from Reddit), I’d put money on the charger being defective.

The OP has updated and added photos after a charger tech came out and pried the plug off the car. He said the same thing had happened to a Rivian.

Updated with photos:

Mach-Lee said:
Let's repost the pictures so forumites can see them. This is what a completely melted/welded DCFC terminal looks like:

Location: https://www.plugshare.com/location/345179

Second plug on the left dispenser, the high amperage CCS handle.

My guess is there was some kind of contamination inside the DC plug, such as a mud dauber nest. Or the plug was worn out and making a really bad connection. I always look inside the holes before plugging it into my car to catch any contamination.

I'm 80% sure the fault lies with the charger/plug side of things. There were probably warning signs in the charger logs such as plug overheating derates. Unfortunately I feel like this is going to end up being a finger pointing exercise.

Wow, I'm amazed it was abandoned in place with the cable attached for a month!

But yeah, melted/stuck plugs is something roadside services are going to have to adapt and deal with because it is going to happen to people. Just like getting locked out of your car, somebody will need to come out and take care of the situation. But it's clear a lot of charging companies haven't even thought about this happening, much less have a procedure in place when it does. That needs to change.

And last, this really brings up the question "What do you do?" if this happens to you. I'd recommend trying to get the charger service guy out there ASAP like this guy did so they can try to remove their plug. Try the emergency release on your own first, but avoid breaking it like he did, pull slowly and firmly instead of a yank. If you can't get it loose yourself it's probably welded/melted, and you may need to go get prying tools to free the plug. It's going to be at your own risk to pry it out, this may be dangerous or you may incur liability. If prying doesn't work, cutting or removing the cable would be the next step, hopefully the charger service guy will show up for this.

Kamuelaflyer · Nov 25, 2022

Did he try the emergency release in the frunk?

Logal727 · Nov 25, 2022

Kamuelaflyer said:
Did he try the emergency release in the frunk?

Yes, there is updates in the comments. It was literally welded to the pins. He somehow convinced a charger tech to come out and pry it out. There’s pics at the link too, scorched pins and melted plastic. Not good.

Keeperofthe7keys · Nov 25, 2022

Logal727 said:
Yes, there is updates in the comments. It was literally welded to the pins. He somehow convinced a charger tech to come out and pry it out. There’s pics at the link too, scorched pins and melted plastic. Not good.

How does this even happen, the port and handle are rated well above what the Mach E actually takes in. Some serious defect on the connector? Maybe cable cooling failed and the charger software failed to reduce power in response for some reason? Interested to see what the charge provider's techs determine the failure is, almost no chance it was on the car side.

Sangsonline · Nov 25, 2022

I am struggling with similar problem. CCS Charging cable has been stuck in MME since 31/10/2022. Ford assistance tried everything to get it released without any luck, the emergency release cable also came out itself( broke off). Ford or Ford assistance could not help so far to release.
MME stayed at the same charger for three and half weeks, with the cable still in stuck in MME.
Yesterday 25/11/2022, after almost four weeks of trying to get the cable released , the charging station company removed their charging cable from the charger itself.
The car has now been towed with the CCS cable in the charge port to ford dealer. So far I understand from ford Netherlands that my car was the first one where they have seen such an problem and as such they have no solution to this problem from their technical department.
I am yet to hear from the dealer about the solution and time line.

I have this MME since June 2021, driven 40000
km with it without any issue but now struggling to get this pony untied.

Mach-Lee · Nov 26, 2022

Let's repost the pictures so forumites can see them. This is what a completely melted/welded DCFC terminal looks like:

Ford Mustang Mach-E DCFC melted / welded to Mach-E charge port during charging session (updated with photos) 😱 OFXrDZD

Ford Mustang Mach-E DCFC melted / welded to Mach-E charge port during charging session (updated with photos) 😱 o8pqvy

Location: https://www.plugshare.com/location/345179

Second plug on the left dispenser, the high amperage CCS handle.

Keeperofthe7keys said:
How does this even happen, the port and handle are rated well above what the Mach E actually takes in. Some serious defect on the connector? Maybe cable cooling failed and the charger software failed to reduce power in response for some reason? Interested to see what the charge provider's techs determine the failure is, almost no chance it was on the car side.

My guess is there was some kind of contamination inside the DC plug, such as a mud dauber nest. Or the plug was worn out and making a really bad connection. I always look inside the holes before plugging it into my car to catch any contamination.

I'm 80% sure the fault lies with the charger/plug side of things. There were probably warning signs in the charger logs such as plug overheating derates. Unfortunately I feel like this is going to end up being a finger pointing exercise.

Sangsonline said:
I am struggling with similar problem. CCS Charging cable has been stuck in MME since 31/10/2022. Ford assistance tried everything to get it released without any luck, the emergency release cable also came out itself( broke off). Ford or Ford assistance could not help so far to release.
MME stayed at the same charger for three and half weeks, with the cable still in stuck in MME.
Yesterday 25/11/2022, after almost four weeks of trying to get the cable released , the charging station company removed their charging cable from the charger itself.
The car has now been towed with the CCS cable in the charge port to ford dealer. So far I understand from ford Netherlands that my car was the first one where they have seen such an problem and as such they have no solution to this problem from their technical department.
I am yet to hear from the dealer about the solution and time line.

I have this MME since June 2021, driven 40000
km with it without any issue but now struggling to get this pony untied.

Wow, I'm amazed it was abandoned in place with the cable attached for a month!

But yeah, melted/stuck plugs is something roadside services are going to have to adapt and deal with because it is going to happen to people. Just like getting locked out of your car, somebody will need to come out and take care of the situation. But it's clear a lot of charging companies haven't even thought about this happening, much less have a procedure in place when it does. That needs to change.

And last, this really brings up the question "What do you do?" if this happens to you. I'd recommend trying to get the charger service guy out there ASAP like this guy did so they can try to remove their plug. Try the emergency release on your own first, but avoid breaking it like he did, pull slowly and firmly instead of a yank. If you can't get it loose yourself it's probably welded/melted, and you may need to go get prying tools to free the plug. It's going to be at your own risk to pry it out, this may be dangerous or you may incur liability. If prying doesn't work, cutting or removing the cable would be the next step, hopefully the charger service guy will show up for this.

Shayne · Nov 26, 2022

^^^ @Mach-Lee

I remember someone here awhile back noting that we should check what we are plugging into the car is not damaged when using someone else's. Remembered that post but a reminder to self I should also remember to do it. The chargers here sit out by themselves unsupervised and poorly maintained.

I am guessing if it looks like the pic above before plugging in we should not plug it in. Leave a note and make a call. Be proactive carry duct tape in the frunk and tape it off

.

Any list of what we should be looking for that would flag a problem. How can we safely clean contacts both the cars and the chargers would be good info.

21st Century Pony · Nov 26, 2022

This is a whole new world.

johnmark · Nov 26, 2022

21st Century Pony said:
This is a whole new world.

And not of the magic carpet ride variety either.

dtbaker61 · Nov 26, 2022

Logal727 said:
This is crazy (reposted from Reddit), I’d put money on the charger being defective.

The OP has updated and added photos after a charger tech came out and pried the plug off the car. He said the same thing had happened to a Rivian.

Updated with photos:

YIKES
.... a worn plug would explain it though.... loose fit, arcing, welding under load.

As DCFC stations get used more, and plug ends get dirty/damaged and not replaced, this might happen more often. I would suggest close visual examination of the condition of a DCFC plug before using it. Blow out any dirt/debris, and if it looks worn or already has evidence of arcing on it..... don't use it!

if you DO get 'welded in place'.... it's going to be a wait for a station tech to power down the charger and remove the handle to free you.... and likely to be a hefty Service to replace the charge port in the car. I wonder if Charger owner/operator insurance will cover the cost of vehicle port replacement?

dtbaker61 · Nov 26, 2022

Shayne said:
^^^ @Mach-Lee

I remember someone here awhile back noting that we should check what we are plugging into the car is not damaged when using someone else's. Remembered that post but a reminder to self I should also remember to do it. The chargers here sit out by themselves unsupervised and poorly maintained.

I am guessing if it looks like the pic above before plugging in we should not plug it in. Leave a note and make a call. Be proactive carry duct tape in the frunk and tape it off .

Any list of what we should be looking for that would flag a problem. How can we safely clean contacts both the cars and the chargers would be good info.

look for any debris first... but then if there is black, pitting, scorching on the contacts, or melted plastic, or damage looking like someone had to pry it off before..... don't use it.

report it to the station owner/operator if any contact info is posted, or tape it off, and maybe report it on plugshare as well.

Electric Goat · Nov 26, 2022

What's the best way to ensure that a plug is clean/un-contaminated? Would using a can of compressed air for electronics on the plug prior to plug-in make sense?

Johnny B · Nov 26, 2022

Electric Goat said:
What's the best way to ensure that a plug is clean/un-contaminated? Would using a can of compressed air for electronics on the plug prior to plug-in make sense?

If you're concerned about this, carrying a can of contact cleaner, like De-Oxit, is going to be more effective than a can of compressed air.

HuntingPudel · Nov 26, 2022

Electric Goat said:
What's the best way to ensure that a plug is clean/un-contaminated? Would using a can of compressed air for electronics on the plug prior to plug-in make sense?

First, visual inspection. If compressed air will get it out, great. If not, move to another station and report this one as being bad.

DYohn · Nov 26, 2022

Sucks for the OP, but things do fail.

DCFC melted / welded to Mach-E charge port during charging session (updated with photos) 😱

Logal727

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Kamuelaflyer

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Logal727

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Keeperofthe7keys

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Sangsonline

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Mach-Lee

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Shayne

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21st Century Pony

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johnmark

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dtbaker61

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dtbaker61

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Electric Goat

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Johnny B

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HuntingPudel

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DYohn

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