Issues during Level2 charging

[danielcb]

Hi everyone.

First, I searched through this forum but I couldn't find any post similar to the issue I have, hence the new post.

I have a 2022 ER AWD model and I think probably ever since I got the car, I'm having issues related to L2 charging. I haven't noticed much because my condo had L3 chargers available for us to use, but as those are broken now and there was new L2 chargers installed near my neighborhood, I started to have to use more L2 charging recently.

I took the car three times to a dealership and it was guaranteed to me that problem was fixed in the last time, by updating some modules. Issue now seems a bit better (charge peaks around 3 kW now) but L2 charging still doesn't work properly.

Before the latest attempt of fix, even something slightly higher than 1 kW would trigger the issue.

The behavior I see is that whenever I plug the car to a L2 station and a while after the car starts to ramp-up the current, there is some sort of signal that resets the connection (probably coming from the car) and I hear the station and car clicking and the charging stopping after current reaches about 12A. At this point, the station stops charging for a while and then resumes ramping up again. This keeps repeating.

Checking CarScanner, I can see that most times, the charging rate reaches around 3.2 to 3.4 kW (in a station that is capable of 16 kW) before resetting. Some times it resets with even a lower current.

I've tried different chargers and they seem to have the same issue.

Using the Ford Mobile Charger in a 110v outlet and L3 charging works without issues, my main problem is L2 charging.

I just did my HBVJB recall recently and when I took the car to the dealership I complained about the problem and it was said this was fixed, now I'm not even sure they even investigated that.

Has anyone had similar issues? If so, have you got it fixed and what was the diagnose?

I'm worried that my on-board charger is broken up and needs to be replaced, which by judging from the whole HVBJB fiasco will mean that my car will probably spend another month or so at the dealership.

EDIT:
Here is a video of the issue: https://www.dropbox.com/scl/fi/e4hs...ey=zjr7r5zqpc4qow9sgflsk5aqn&st=p28a78o5&dl=0

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[Mach-Lee]

There are some known compatibility issues with those ChargePoint chargers. Some aspect of the J1772 signal is out of spec, and that cause them to start and stop charging. Does it always have that problem or only sometimes?

I also want you to try a different brand of Level 2 station (not ChargePoint) and see if that works.

You have this code, so make sure the plug is fully inserted: https://www.macheforum.com/site/thr...24-code-and-possible-12v-battery-drain.23525/ The code could also be from some stray voltage on the proximity pilot circuit if monitored by the EVSE (I think the ChargePoints do).

What is the software version on those ChargePoint units? I have a hunch it's out of date.

 

[danielcb]

I've tested different brands of EVSEs, all of them have the same exact behavior.

The charging always resets at around 12A or ~3.7kW, no matter which charger I use. If the charger is not capable of doing more than 3.4kW, the car is able to charge. This is either still some firmware issue or indeed I have a bad onboard charger...

 

[Mach-Lee]

I've tested different brands of EVSEs, all of them have the same exact behavior.

The charging always resets at around 12A or ~3.7kW, no matter which charger I use. If the charger is not capable of doing more than 3.4kW, the car is able to charge. This is either still some firmware issue or indeed I have a bad onboard charger...

Ah. When did this start? I'm not aware of that issue happening with every singe EVSE tried, so it's probably a hardware issue. Either the charger or charge port. I had the same version of software you did and it's been rock solid charging for me.

You should clean inspect your charge port in case it's a connection issue or there's damage: https://www.macheforum.com/site/threads/how-to-clean-your-charge-port.29901/

 

[danielcb]

Here are some other videos:

Different EVSE: https://www.dropbox.com/scl/fi/799a...ey=mc73v9p0a05axihfwoyxiks6a&st=7reeetp4&dl=0

CarScanner: https://www.dropbox.com/scl/fi/s2g1...ey=nbe8175kx9w0wfbv7g2hcqru5&st=i6ldj41b&dl=0

 

[danielcb]

Ah. When did this start? I'm not aware of that issue happening with every singe EVSE tried, so it's probably a hardware issue. Either the charger or charge port.

You should clean inspect your charge port in case it's a connection issue or there's damage: https://www.macheforum.com/site/threads/how-to-clean-your-charge-port.29901/

To be honest, I'm not sure when it started.

In my building I used to have DCFC available ( 50 kW units only though ), but as those broken down and the strata still has not fixed them I found myself in the need of using more L2 public chargers in the neighborhood and at the office.

Actually, the few times I tried to charge my car in L2 EVSEs before, even anything less than 3kW was causing the car to stop. Only L1 was working somewhat reliable. After my HVBJB recall, I'm seeing this current behavior of anything higher than 3.4 kW causing the charging to stop.

The worst part is that now I will have to start a dealership hunt as I have zero trust in the previous (and sole) dealership I was working with and that started the Thread

 

[Mach-Lee]

Here are some other videos:

Different EVSE: https://www.dropbox.com/scl/fi/799a...ey=mc73v9p0a05axihfwoyxiks6a&st=7reeetp4&dl=0

CarScanner: https://www.dropbox.com/scl/fi/s2g1...ey=nbe8175kx9w0wfbv7g2hcqru5&st=i6ldj41b&dl=0

FYI if you use Car Scanner you should look at the relevant AC charging parameters, the window you were on is not that useful for Level 2. These are what you want and what it should look like while charging:

They should all be relatively stable while charging. You'll have to see which number gets messed up first when it stops charging and that will be a clue.

And the temps:

 

[danielcb]

FYI if you use Car Scanner you should look at the relevant AC charging parameters, the window you were on is not that useful for Level 2. These are what you want and what it should look like while charging:

They should all be relatively stable while charging. You'll have to see which number gets messed up first when it stops charging and that will be a clue.

And the temps:

I will re-test again in some EVSEs and get some screen recordings of those parameters.

Thank you!

 

[danielcb]

Hello all.

Lots of things happened recently and thus I'd like to give an update about the current state of my issue.

TLDR;

Took my car back to the same dearlership and now they were working with Ford engineering to fix the issue.

Update:

I got a call back from one of the dealership managers about a survey sent to me about my last service appointment, where I obviously selected all as 0 and left a pretty long list com complaints and points they missed regarding my service.

During this call, I went through all the points of problems and specifically how my car was still not charging properly using L2 chargers over than 3.4 kW. The manager setted up an appointment and a loaner for me the next day so they try and fix the issue (and regain my trust). Meanwhile I sent them some of the videos and data I gathered using CarScanner.
When I dropped the car at the Dealership, I asked them test with the actual Ford mobile charger again, where the issue still happens, and finally they were able to see the issue happening and also get some DTC codes related to the charging stopping (which should have been checked since the first time, as they should be there in the first place).

They tried some procedures, like changing the harness from charging port to the SOBDM, master reset the car and some other things without much luck. At this point they engaged with Ford's engineers to troubleshoot the issue.

They also were able to get a new SOBDM from another dealership but right before they installed it, Ford's engineering team asked them to pause the procedure and have the dealership technicians perform a live troubleshooting session with a camera, so the engineers could see what the technicians were seeing.

I'm still waiting on feedback if they actually changed the SOBDM or not. Will update this again, as soon as I get more information.






They did lots of tests, even fully reset the car and changing the cable connecting the charging port to the SOBDM. All without much lucky.
They were preparing to change SOBDMm but engineering asked to to pause that and have a remove diagnostic session which one of the technicians using a camera.

 

[Shayne]

You are being sent on a wild goose chase. There is major problems with Fords L2 charging that is well documented here. We have definitely heard about this before and you are not the only one to have slow L2 charging speeds.

L2 charging speed

L2 melts

Many of us are experiencing really slow L2 charging speed now. To date no transparency, help or fix from Ford. In fact the melting fix software is on hold and can not be installed at service locations right now. 3 KW is slow the slowest I have seen mine is 4 KW on a 40 amp charger. Do not blame the EVSE it is the car.

Edit: Should have linked this TSB-2410 also.

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