Major problems getting Ford Connected charger installed

[Elisabethlaw]

Hi there. We have now had two different master electricians come out trying to get our Ford Connected charge station installed at our home. There is power to the station. It was wired properly. But the station will not ever move off of the solid amber colored light. We have gotten numerous error messages but the most consistent one is “Charge Station Faulted”. This message appears through the Ford Pass app and the “Charge Station” section of that app under energy.

We have called the FordEV specialist line at 800-392-3673. They stated we have to file a claim but not much more information beyond that. Could it possibly be a faulty charger? One of our electricians even installed a Ford Connected Charger down the street at our neighbors house… but this was two years ago and the charger was slightly different then.

Any ideas or help? We are almost a month in to owning this vehicle and not being able to charge at home has become frustrating.

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[bshaw]

We have now had two different master electricians come out trying to get our Ford Connected charge station installed at our home. There is power to the station. It was wired properly. But the station will not ever move off of the solid amber colored light. We have gotten numerous error messages but the most consistent one is “Charge Station Faulted”. This message appears through the Ford Pass app and the “Charge Station” section of that app under energy.

Herein lies one of the problems with choosing a hardwired EVSE option. The master electrician is unlikely qualified to troubleshoot problems with installed electronics.

When I had my EVSE installed, I had the electrician install the breaker, wiring & 14-50 outlet and check it was correct with his voltmeter. Electrician left and I plugged in the EVSE on my own. If the EVSE malfunctions, I replace it on my own without touching any electrical wiring.

Would you ask a master electrician to diagnose a problem with your refrigerator, microwave, dishwasher or electric oven? No, that sounds ridiculous.

Going hardwired to squeeze out the last 8A of charging speed capacity just isn't worth the tradeoffs (to me at least).

 

[Elisabethlaw]

Herein lies one of the problems with choosing a hardwired EVSE option. The master electrician is unlikely qualified to troubleshoot problems with installed electronics.

When I had my EVSE installed, I had the electrician install the breaker, wiring & 14-50 outlet and check it was correct with his voltmeter. Electrician left and I plugged in the EVSE on my own. If the EVSE malfunctions, I replace it on my own without touching any electrical wiring.

Would you ask a master electrician to diagnose a problem with your refrigerator, microwave, dishwasher or electric oven? No, that sounds ridiculous.

Going hardwired to squeeze out the last 8A of charging speed capacity just isn't worth the tradeoffs (to me at least).

So you are saying I just should have had the 240 plug installed and charged it via the mobile charger that way? Or what’s a solution you suggest?

I see where you are going with this… and it makes sense…

 

[Maquis]

Herein lies one of the problems with choosing a hardwired EVSE option. The master electrician is unlikely qualified to troubleshoot problems with installed electronics.

When I had my EVSE installed, I had the electrician install the breaker, wiring & 14-50 outlet and check it was correct with his voltmeter. Electrician left and I plugged in the EVSE on my own. If the EVSE malfunctions, I replace it on my own without touching any electrical wiring.

Would you ask a master electrician to diagnose a problem with your refrigerator, microwave, dishwasher or electric oven? No, that sounds ridiculous.

Going hardwired to squeeze out the last 8A of charging speed capacity just isn't worth the tradeoffs (to me at least).

By that logic, you should only have plug-in window air conditioners instead of a hard-wired central unit.

 

[bshaw]

So you are saying I just should have had the 240 plug installed and charged it via the mobile charger that way? Or what’s a solution you suggest?

I see where you are going with this… and it makes sense…

The Ford mobile charger has given people problems after using it for regular charging, so I wouldn't recommend that option.
But, there are lots of 3rd party EVSEs on the market that use a 14-50 outlet.

I know its a little too late since you already purchased the Ford Connected Charge station, but a suggestion for others I guess.

 

[bshaw]

By that logic, you should only have plug-in window air conditioners instead of a hard-wired central unit.

Just trying to keep EV things more simple. But, yea I guess your central AC is going to be hardwired.

 

[Maquis]

One of two scenarios are likely (no particular order):
1. The unit is defective.
2. The signal cable is not fully plugged in. It’s the orange to brown connection on the left side of this picture:

 

[Elisabethlaw]

One of two scenarios are likely (no particular order):
1. The unit is defective.
2. The signal cable is not fully plugged in. It’s the orange to brown connection on the left side of this picture:

 

[Maquis]

It looks like the connection methods have changed since my 2020 model. Make sure the small orange wire is fully plugged in. Your manual should show exactly where it goes.

Also, the incoming wire appears to be #6 type NM cable run in flex conduit. Wiring with a minimum ampacity of 60A is required to utilize the full output of 48A. #6 NM is only rated for 55A, so your EVSE should be set to 40A max instead of 48. This is not what’s causing your current problem, though.

 

[bshaw]

Flip the breaker off before putting your hands inside there.

 

[dtbaker61]

The Ford mobile charger has given people problems after using it for regular charging, so I wouldn't recommend that option.

Who has had problems with the Mobile charger? Most threads I've seen the issue turned out to be poorly installed outlets and/or ambient heat problems.

I've used my mobile since day one for both my MME and wife's PHEV. combines miles charged at about 75,000 miles now.

regardless.... the OP is having a problem w the hardwired EVSE, not the mobile, so why slam the mobile ?

in skimming the connected install manual at https://chargers.ford.com/ford-connected-charge-station, I would ask the following:
- are you SURE that the breaker for the charger is NOT a GFCI ? if it is, you will get false trips, the manual says there is internal GFCI.

then, did you read thru the install manual, and follow the steps on page 7 to 'commission' your charger ID ?

https://chargers.ford.com/gcs/B2C/c...tion_Installation_Manual_final_May_2023_1.pdf

 

[dtbaker61]

the other thing to check, especially if installed by an electrician rather than ford-trained installer, is that they set the DIP switches correctly. I dunno what the factory defaults are, but it might not be correct for your install:

https://www.macheforum.com/site/threads/new-install-ford-connected-charge-station-problems.36047/

 

[leemoknows]

the other thing to check, especially if installed by an electrician rather than ford-trained installer, is that they set the DIP switches correctly. I dunno what the factory defaults are, but it might not be correct for your install:

https://www.macheforum.com/site/threads/new-install-ford-connected-charge-station-problems.36047/

That's one of the issues I had. I went ahead and looked since the electrician didn't mention anything to me other than just "it's mounted and connected". It was set on 20A. I had a 100A service installed in my garage and had the charger put on a 60A breaker (by the same electrician). I opened up the Ford charger and set the dip switches properly to 48A/60A.

My problem is that I can't get the charger to show up in the Ford app. I can get it on my network and it shows up as connected in my router. Where it stops during install is "Connecting your station to your app. This should only take a few seconds". Very frustrating lol.

 

[dtbaker61]

That's one of the issues I had. I went ahead and looked since the electrician didn't mention anything to me other than just "it's mounted and connected". It was set on 20A. I had a 100A service installed in my garage and had the charger put on a 60A breaker (by the same electrician). I opened up the Ford charger and set the dip switches properly to 48A/60A.

My problem is that I can't get the charger to show up in the Ford app. I can get it on my network and it shows up as connected in my router. Where it stops during install is "Connecting your station to your app. This should only take a few seconds". Very frustrating lol.

YIKES!
go back and reduce the max current before using!

If you have a 60amp breaker, and have verified that the conductors to the charger are 6ga, you might consider setting the max current to 48amps, but NOT 60!

because ev chargers present a continuous load for more than 2 hours, you MUST derate the max current a specific wire carries by at least 20% to prevent overheating.

 

[leemoknows]

YIKES!
go back and reduce the max current before using!

If you have a 60amp breaker, and have verified that the conductors to the charger are 6ga, you might consider setting the max current to 48amps, but NOT 60!

because ev chargers present a continuous load for more than 2 hours, you MUST derate the max current a specific wire carries by at least 20% to prevent overheating.

48A/60A is peak charger dip switch setting. It just means you can charge up to 48A on a 60A breaker. Yes, they used the proper gauge wire. That was the whole reason I had a 100A service installed in my garage. I wanted it to be able to use all of what the charge could do.

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