Ford Connected Charge Station Issues (Electrical Contractor)

[azruna]

Hello all, I finished installing my second Ford Connected charger and am running into an issue.
As background, I am an electrician and my first Ford Connected Charger set for a 30amp circuit breaker worked perfectly fine. But the one I am currently having issues with is set to work on a 40amp circuit breaker.
I suspect there is a problem with the charge station itself but would like to see if anyone here has any thoughts or opinions while the customer waits to hear back from Ford.

here is my report on the issue(s):

Problem:

-Ford Connected Charge Station tripping 40A breaker.

Report:

-Tested Voltage at 237VAC.. OKAY

-Tested current draw at about 50-55Amps input… NOT OKAY (see picture 1)

-Checked Dip switch settings… D1-0, D2-1, D3-1, D4-0, D5-0 (see picture 2) ….. CORRECT according to installation manual and using the screen-printed “Function selection” indication on PCB showing 1 – 0 positions.

-Tried alternative dip switch settings (see picture 3 and picture 4)… Determined if setting D1-0, D2-1, D3-0, D4-1, D5-1 were used the charger would operate at ~27 Amps input current. With D5 set to 0 charger would operate at 50-55 Amps. This is contrary to the functionality explained in the installation instructions.

Notes:

-Bluetooth functionality with charger not working with iphone app.

-Mach E vehicle error “Charge Settings Conflict”

-No issue with electrical installation. Suggest contacting Ford’s technical service department for further instructions.

Sponsored

 

[Garbone]

Should be on a circuit that can handle 60amps. #6 THHN and a 60 amp breaker. Something wrong with the charger dips.

 

[macchiaz-o]

Should be on a circuit that can handle 60amps. #6 THHN and a 60 amp breaker. Nothing wrong with the charger.

No. The EVSE is configurable to match the circuit rating.

 

[Garbone]

No. The EVSE is configurable to match the circuit rating.

Ya, screwed that up....

 

[azruna]

Should be on a circuit that can handle 60amps. #6 THHN and a 60 amp breaker. Something wrong with the charger dips.

That's not correct according to the installation manual. These chargers can be set for different sized circuit breakers via dip switch settings, as I have done in the past with zero issue and as per the installation instructions.

 

[phidauex]

The settings look right to me for the limitation to 32A. I don't see any obvious test points for checking the DIP switch operation, but might be worth flipping the dip switches back and forth a few times in case one of them is sticky. It looks like the default is always to 48A if there is an "invalid" switch combination, so if one of them isn't landing right it makes sense that it would jump up to the 48A setting.

 

[azruna]

The settings look right to me for the limitation to 32A. I don't see any obvious test points for checking the DIP switch operation, but might be worth flipping the dip switches back and forth a few times in case one of them is sticky. It looks like the default is always to 48A if there is an "invalid" switch combination, so if one of them isn't landing right it makes sense that it would jump up to the 48A setting.

that was my innitial thought as well. I did flip them back and forth in case they were not making a good connection. This didnt seem to help.
Also, what really threw my for a loop is that it reverts to the 30cb setting if I flip D5 to “1”. This “should” default to 48a 60a cb setting.

 

[hybrid2bev]

that was my innitial thought as well. I did flip them back and forth in case they were not making a good connection. This didnt seem to help.
Also, what really threw my for a loop is that it reverts to the 30cb setting if I flip D5 to “1”. This “should” default to 48a 60a cb setting.

I thought someone posted on here before to ignore the 1 -0 printed on the circuit board and to use the ON indicator on the switch assembly itself.

 

[azruna]

I thought someone posted on here before to ignore the 1 -0 printed on the circuit board and to use the ON indicator on the switch assembly itself.

I saw the post. And it claims opposite to what you say. It claims to use the screen printed functions. Not the dip switch “on” designation.
Ridiculous design idea from whoever manufactures this thing.

 

[macchiaz-o]

I saw the post. And it claims opposite to what you say. It claims to use the screen printed functions. Not the dip switch “on” designation.
Ridiculous design idea from whoever manufactures this thing.

Agreed. I went by the 0 and 1 printed on the circuit board and not the ON label on the switch board.

Have you called the support phone number yet? I'm wondering if they have a support rep who can speak to electricians directly?

 

[Carsinmyblood]

Agreed. I went by the 0 and 1 printed on the circuit board and not the ON label on the switch board.

Have you called the support phone number yet? I'm wondering if they have a support rep who can speak to electricians directly?

I'd have to wonder about the rest of what's in the box.

 

[azruna]

Agreed. I went by the 0 and 1 printed on the circuit board and not the ON label on the switch board.

Have you called the support phone number yet? I'm wondering if they have a support rep who can speak to electricians directly?

I've only contacted the ford dealership and they are going to go in tomorrow and see if they can force an update and will contact the manufacturer with our concerns. Hopefully we can get this figured out for the customer.

 

[Jimrpa]

D1 must be set to 1. I was caught out by this. The instructions are poorly written.

 

[azruna]

D1 must be set to 1. I was caught out by this. The instructions are poorly written.

according to the instructions d1 “should” be set to 0. 1 is called “invalid default 48amps.”

 

[Jimrpa]

according to the instructions d1 “should” be set to 0. 1 is called “invalid default 48amps.”

I’m too lazy to go down and remove the covers, but I had to flip it to the opposite position from the one it was in when it came from the factory. If I recall, 1 Is OFF?

Sponsored