Car Randomly Stops Charging

[Sully]

Not to derail the thread, but your symptoms are similar to what happened to me Sunday night. Amber ring, SVS, HV Battery warning. Let it sit for about 45min and I got an "accidental unplug" message in FP about 45min after unplugging. Also have a CP HomeFlex.

I've done 2 small charges since without issue

I am still continuing to have this issue. I have had a couple charges where it was fine, but lately I can't get through a charge without it happening. After the only amber ring we have had since owning it, I have been able to charge maybe 3 times without it just going to the "Plugged in not charging" after 1-2 hours.

I am starting to think if this is update related because we have not had issues before. I know it is entirely possible there is an actual issue unrelated to the updates, but I cannot seem to narrow down specifically what it is.

We got the Ford Power Up 4.2.3 on March 29th. Amber ring happened April 2nd. Got the next OTA (4.2.4) on April 5th. Had two charges after without issues. However, since April 8th, I have had issues with just the "Plugged in not charging" message. I haven't seen any "Charge fault" on the CPHF or the car.

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[SWO]

I am still continuing to have this issue. I have had a couple charges where it was fine, but lately I can't get through a charge without it happening. After the only amber ring we have had since owning it, I have been able to charge maybe 3 times without it just going to the "Plugged in not charging" after 1-2 hours.

I am starting to think if this is update related because we have not had issues before. I know it is entirely possible there is an actual issue unrelated to the updates, but I cannot seem to narrow down specifically what it is.

We got the Ford Power Up 4.2.3 on March 29th. Amber ring happened April 2nd. Got the next OTA (4.2.4) on April 5th. Had two charges after without issues. However, since April 8th, I have had issues with just the "Plugged in not charging" message. I haven't seen any "Charge fault" on the CPHF or the car.

Curious - what mileage is your vehicle at? I'm just under 13k right now.

Did you try charging at a lower amperage? I've done 2 charge sessions since without issue, but they were relatively short. I want to do a full 10-90% charge at home with it still.

 

[Sully]

Curious - what mileage is your vehicle at? I'm just under 13k right now.

Did you try charging at a lower amperage? I've done 2 charge sessions since without issue, but they were relatively short. I want to do a full 10-90% charge at home with it still.

Car is just under 21,000 miles. I did schedule the 20,000 mile service this morning and told them I was having issues charging, so at least they can take a look while it is there for the routine service.

I normally charge to 90%. Today, the car was at 39% SOC when I plugged in. It stopped after 2 hours - only got to 63% SOC. I waited about 45 minutes and plugged it back in to see if I can at least get it back to 90% since it is our daily driver on the weekends (and my daily driver all the time). We seem to think it is the car itself that has the issue, but not sure if it is hardware or software at this point.

I haven't tried a lower amperage on the CPHF (yet!). We currently have it hardwired on a 60amp breaker. I do have the ford mobile charger as well, but only a regular outlet which will be super slow charging. These are two options I plan to try out this week.

Last option is to charge it daily with super short charges (less than 10% to bring/keep it to 90%) which isn't ideal, but I will if I need to.

 

[stratigary]

Car is just under 21,000 miles. I did schedule the 20,000 mile service this morning and told them I was having issues charging, so at least they can take a look while it is there for the routine service.

I normally charge to 90%. Today, the car was at 39% SOC when I plugged in. It stopped after 2 hours - only got to 63% SOC. I waited about 45 minutes and plugged it back in to see if I can at least get it back to 90% since it is our daily driver on the weekends (and my daily driver all the time). We seem to think it is the car itself that has the issue, but not sure if it is hardware or software at this point.

I haven't tried a lower amperage on the CPHF (yet!). We currently have it hardwired on a 60amp breaker. I do have the ford mobile charger as well, but only a regular outlet which will be super slow charging. These are two options I plan to try out this week.

Last option is to charge it daily with super short charges (less than 10% to bring/keep it to 90%) which isn't ideal, but I will if I need to.

This does sound exactly like the same issue I had. The charge fault would only occur for me when I was charging at high amperage (48A) and would go away If I cranked it down to 32A or used another level 2 charger at a lower amperage.

If the issue goes away when charging at a lower amperage it sounds like you are having the same issue as I did and should be covered under the HV warranty.

 

[stratigary]

Thanks, I appreciate the information. Do you know how much that would cost to replace? My car has been out of warantee for a while.

Also, it's been pretty chilly at night here, I'm wondering if this issue will pop up again when it starts to heat up outside? I didn't check the days that it happened, but we've had a few warmer days these past two weeks... wonder if there's a correlation.

I will check my records when I get back, but it honestly should be covered under the 8yr/100K HV battery and electronics warranty.

If you're able, try lowering the charge amperage on your EVSE and see if the problem goes away. Mine would only pop up when charging above 40A.

 

[Sully]

This does sound exactly like the same issue I had. The charge fault would only occur for me when I was charging at high amperage (48A) and would go away If I cranked it down to 32A or used another level 2 charger at a lower amperage.

If the issue goes away when charging at a lower amperage it sounds like you are having the same issue as I did and should be covered under the HV warranty.

Removed and set up my CPHF again but with a 40A breaker (32A) and it has charged for 5 hours without any issues. I will keep it here until I figure out what the issue is.

 

[DanCoon]

So far mine is still charging fine without any error codes. But...

I don't know how hot the on board charge connection should get while charging, but I did hold my hand to it after unplugging and noticed that it was almost too hot to keep my hand there. If anybody has any specs to point to I'll check it with a laser thermometer.

 

[stratigary]

Removed and set up my CPHF again but with a 40A breaker (32A) and it has charged for 5 hours without any issues. I will keep it here until I figure out what the issue is.

I'm pretty confident you're having the same issue I did, especially if you can charge successfully at 32A.

You should definitely take it into Ford to have them look at it. They'll have to keep it for some time to diagnose but they should be able to figure out what is going on

 

[stratigary]

So far mine is still charging fine without any error codes. But...

I don't know how hot the on board charge connection should get while charging, but I did hold my hand to it after unplugging and noticed that it was almost too hot to keep my hand there. If anybody has any specs to point to I'll check it with a laser thermometer.

I think it can get pretty hot. I'll post a graph of mine charging at 48A that eventually got too hot at around 175F. At 32A it was hitting about 130F.

However, this was the data before I had the charge port replaced under warranty. I'll try and get recent data to see if it's still that high.

 

[SeaKayaker4Life]

After 9 months of ownership my charge port died completely and my dealer replaced it at no charge. I suggest verifying if your problem occurs using other L2 chargers or with the included Ford mobile charger plugged into a 120V outlet. In my case, the car would not charge at all.

 

[Maquis]

So far mine is still charging fine without any error codes. But...

I don't know how hot the on board charge connection should get while charging, but I did hold my hand to it after unplugging and noticed that it was almost too hot to keep my hand there. If anybody has any specs to point to I'll check it with a laser thermometer.

I don’t have anything quantitative, but I’ve felt mine after charging at 48A for hours and it was just warm to the touch.

 

[Kabish]

Oddly enough I received a Fordpass message at 4:22am this morning saying my car failed to charge. Mind you the charge was supposed to start at 12am, no idea why it waited to notify me.. Regardless though, I ignored it cause I knew I had a good enough charge.

Came out to the car at 7am and had the red ring. Was really creepy, I opened my car door and my car did not welcome me in with open arms like normal! It was such an odd experience getting in with no lights on or the system booting up. Thought for sure it was not going to turn on as I had tired to remote unlock the car for my kid to put her school stuff in while I was getting my work stuff. Sure enough though, car turned on without any "issue".

However, all the car alerts were coming through some type of internal speaker vs the sound system. I felt like I was playing a 1980's video game while driving down the freeway lol It did the same unusual noise for the proximity and seat belt alerts as well.

Hopefully it charges tonight, defiantly don't have the range for tomorrow commute

 

[DanCoon]

Found this thread from last year that might be helpful...

https://www.macheforum.com/site/thr...a-on-hv-ac-charger-coupler-temperature.15860/

I finally found the senors in car scanner. The AC coupler temperature on mine was climbing over 240F on one sensor before I had to get out of the car. I'll do a more thourough test on the temperature later this week when I have the time.

 

[Mach-Lee]

Found this thread from last year that might be helpful...

https://www.macheforum.com/site/thr...a-on-hv-ac-charger-coupler-temperature.15860/

I finally found the senors in car scanner. The AC coupler temperature on mine was climbing over 240F on one sensor before I had to get out of the car. I'll do a more thourough test on the temperature later this week when I have the time.

Holy s***, you need to get that replaced ASAP. You will probably need to buy a new EVSE cord as well since that probably melted too. Why don't you carefully inspect the charge port and J1772 for signs of melting?

 

[stratigary]

Holy s***, you need to get that replaced ASAP. You will probably need to buy a new EVSE cord as well since that probably melted too. Why don't you carefully inspect the charge port and J1772 for signs of melting?

I think he's looking at a post of mine from last year.

It turns out that, in my case, the temperature wasn't really getting that high in the charge port. There was a faulty temperature sensor that was reporting temperatures much higher than were actually present and causing the charging session to shut down.

They had to replace the charge port and the entire cable that goes from it to the onboard charger to fix the problem. Mine has been find ever since.

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