Emporia charger completes but ends session with fault

hack-e

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Same - EVCharger-467
Thanks for reporting. It would appear the Emporia firmware version does not correlate with the fault.
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hack-e

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GatorJ_MME

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Could you try lowering your amperage? I haven’t come up with a reason why it would change the behavior assuming there are no real components on the car side of the Emporia’s relay, but it is at least a difference in our setups.
 

hack-e

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Mach-Lee

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I have never seen the fault occur when pressing the release button while charging. Instead it only occurs when the MME reaches its charging target (80% in my case). I get the charge complete notice immediately followed by the fault notice:
1000001556.webp
If you unplug it within 3 seconds of pressing the button it won’t set the fault. You have to press and hold the latch button for 10 seconds without unplugging to see if the fault sets.
 


Snakebitten

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I have my Emporium set at 28A for no good reason. But it is what I had it set at for the Leaf because that's as fast as it could gulp electrons.

I have the Mach-E "target" at 70% in FordPass.
So when the car hits 70%, it tells whatever it tells to the Emporium and the Emporium sends me the alert.

I just got the alert a few minutes ago. This is what the Emporium app says:

Ford Mustang Mach-E Emporia charger completes but ends session with fault 1000022663


And this is FordPass:

Ford Mustang Mach-E Emporia charger completes but ends session with fault 1000022665


If I am still awake when the car hits its charging target, I usually press the

Ford Mustang Mach-E Emporia charger completes but ends session with fault 1000022666


And it changes the Emporium mode to

Ford Mustang Mach-E Emporia charger completes but ends session with fault 1000022668
 

GatorJ_MME

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This looks normal to me - the Mach E reached your charge limit, so tells the Emporia to stop sending charge.
 
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Snakebitten

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This looks normal to me - the Mach E reached your charge limit, so tells the Emporia to stop sending charge.
Yeah. I should have been clearer, but I was in fact documenting with graphics what I believe is Normal, with a Mach-E using target SOC and Emporium plugged in with no scheduling parameters.
 

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The J1772 specification says power needs to be shut off within 3 seconds of switching to state B (idle). Do you think the Emporia is taking longer than 3 seconds to shut off?

Press the release button while charging and time how long it takes the Emporia EVSE to click with a stopwatch.
I disconnected the Emporia so can't measure how long it takes for the contactor to open. It didn't trigger a fault every time I charged, only faulted every three days or so. When the car was a load on the EVSE, I always waited for the contactor to open before I pulled the plug out and my guess is it took at least 3 seconds.
 

GatorJ_MME

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For those that have the issue, do you typically run at 40 or 48A, and also plug in at a low state of charge? Is it possible we are seeing something akin to the HVJB where the contactor is overheating / sticking?

I have always run my Emporia at 28A except for the first day or two after I got my car, and it's rare that I plug in below 50%. My charging cycles can take upwards of 4 hours, but it should be at almost (or less than) half the rated current (I'm assuming the contactor is rated for >48A).
 

hack-e

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If you unplug it within 3 seconds of pressing the button it won’t set the fault. You have to press and hold the latch button for 10 seconds without unplugging to see if the fault sets.
I misremembered what you said on timing but I ran your test this morning. I first left the Emporia set to 48A since that's a known condition where it happens. I repeatedly plugged it in and let it ramp up to full power then press the unlatch button on the handle and held for 5-8 sec before pulling out. At the 11th time I got the charge fault. That closely matches my 10% estimation. I did 48A two more times for a total of 13 with only the one fault. So that's good that I have a relatively quick way to repeat the fault should we get a "fix" for it (or if I figure out a way to monitor the power and control signals directly to determine who's at fault).

I then dropped to 28A and repeated the test 13 times until my car reached its 80% and stopped requesting power. I will try 28A again tomorrow.
Ford Mustang Mach-E Emporia charger completes but ends session with fault 1712157871468-5y
 

Mach-Lee

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I misremembered what you said on timing but I ran your test this morning. I first left the Emporia set to 48A since that's a known condition where it happens. I repeatedly plugged it in and let it ramp up to full power then press the unlatch button on the handle and held for 5-8 sec before pulling out. At the 11th time I got the charge fault. That closely matches my 10% estimation. I did 48A two more times for a total of 13 with only the one fault. So that's good that I have a relatively quick way to repeat the fault should we get a "fix" for it (or if I figure out a way to monitor the power and control signals directly to determine who's at fault).

I then dropped to 28A and repeated the test 13 times until my car reached its 80% and stopped requesting power. I will try 28A again tomorrow.
1712157871468-5y.webp
FYI starting and stopping charging too many times in a short period can cause a different error (precharge resistor overheat protection).

Did you happen to pay attention to how long it took the Emporia to click after pressing the button?

I don’t think it’s related to the charge rate because it happens at the end of charging.
 

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I have this problem often when using excess solar especially on cloudy days as charging turns off everytime a cloud passes and generation drops after a few cycles the car detects the fault likely due to power turning off\ on. Reducing the amperage seems to help reduce the swings somewhat, using peak demand at ~2kw seems to work most of the time as charging can drop to a few amps instead of shutting off. Tesla charge on solar I think will give a minimum of 6A to prevent the cycling which might be something emporia could add to solve these issues.
 

hack-e

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Did you happen to pay attention to how long it took the Emporia to click after pressing the button?
Would that be in the handle of the Emporia or in the wall box? My Emporia wall box was on the other side of a closed garage door. However, I did hear an immediate clicking every time I pressed the handle button. No delay. I just couldn't tell if that was from the car or the charger handle.
 

Mach-Lee

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I have this problem often when using excess solar especially on cloudy days as charging turns off everytime a cloud passes and generation drops after a few cycles the car detects the fault likely due to power turning off\ on. Reducing the amperage seems to help reduce the swings somewhat, using peak demand at ~2kw seems to work most of the time as charging can drop to a few amps instead of shutting off. Tesla charge on solar I think will give a minimum of 6A to prevent the cycling which might be something emporia could add to solve these issues.
Charge should not stop when a cloud goes by, if so it’s set up wrong. If the solar production rate drops, it should continue charging at the minimum rate (6A) and ramp up and down with the sun. But not stop until the car is full. Might need to check your settings or complain to Emporia if they’re implementing it wrong.

Would that be in the handle of the Emporia or in the wall box? My Emporia wall box was on the other side of a closed garage door. However, I did hear an immediate clicking every time I pressed the handle button. No delay. I just couldn't tell if that was from the car or the charger handle.
The car will click immediately, the EVSE will be delayed but needs to click within 3 seconds of button press.
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