Charge Station Pro DOA

[phxdonald]

Had our Charge Station Pro with Home Integration System installed a few weeks ago, before we took delivery of our truck. Took delivery on 5/27 and when we went to charge her up, the charger immediately went to a FAULT. Tried to get ahold of Sunrun, but they have been unresponsive, so I contacted the third party electrician that Sunrun subcontracted with. They came out this morning and determined that the charger needs to be replaced. They said that 25% of the chargers that they have installed have had to be replaced due to failures. That's a pretty poor success rate for Ford. Hope they get that figured out soon. Has anyone else experienced the same?

Sponsored

 

[TaxmanHog]

Had our Charge Station Pro with Home Integration System installed a few weeks ago, before we took delivery of our truck. Took delivery on 5/27 and when we went to charge her up, the charger immediately went to a FAULT. Tried to get ahold of Sunrun, but they have been unresponsive, so I contacted the third party electrician that Sunrun subcontracted with. They came out this morning and determined that the charger needs to be replaced. They said that 25% of the chargers that they have installed have had to be replaced due to failures. That's a pretty poor success rate for Ford. Hope they get that figured out soon. Has anyone else experienced the same?

Have you tried power cycling the FCSP?

Unplug truck from the EVSE, switch your 100 amp break off for 5 minutes, then switch on, let the unit run for ~15-30 minutes to finish any updates that might have been pending.

If it's still failing, confirm what the firmware version is, this is the latest on my unit, as viewed on Fordpass connected charge station tile, settings menu, if you do not have this, leave the truck unplugged overnight to allow a download and update to post, repeat the power cycling.

 

[phxdonald]

Have you tried power cycling the FCSP?

Unplug truck from the EVSE, switch your 100 amp break off for 5 minutes, then switch on, let the unit run for ~15-30 minutes to finish any updates that might have been pending.

If it's still failing, confirm what the firmware version is, this is the latest on my unit, as viewed on Fordpass connected charge station tile, settings menu, if you do not have this, leave the truck unplugged overnight to allow a download and update to post, repeat the power cycling.

My software version is 2.112.64:0. We have tried your suggestion, but the device is fried. You can actually smell burnt electronics on it. Factory reset button doesn't respond. Cannot connect to charger with app. Installing electrician has confirmed that this is the 5th unit that they have installed that has failed in the same exact way.

 

[RickLightning]

It's really a shame. Ford Mobile Charger - not good. Ford Charge Station Pro, looking to have issued.

I installed a JuiceBox 48 2 years ago, works great. Put in another one last month. FCSP is sitting in a box, guess I will more aggressively work to sell it.

 

[Heliian]

Installing electrician has confirmed that this is the 5th unit that they have installed that has failed in the same exact way.

Then it's probably the electrician. It would seem unlikely that a single electrician has installed enough of these to see that high of a failure rate.

If they actually have installed dozens, there were issues with fcsp production a while back, maybe they got a bad batch from that run?

 

[Zprime29]

Then it's probably the electrician. It would seem unlikely that a single electrician has installed enough of these to see that high of a failure rate.

If they actually have installed dozens, there were issues with fcsp production a while back, maybe they got a bad batch from that run?

This was my immediate thought. While there are many reports of issues connecting, this is the first I've heard of it literally burning out. A one off, I could believe. The fact that this one electrician is having this many fail, in my mind, implies they are doing something wrong.

 

[VTbuckeye]

This was my immediate thought. While there are many reports of issues connecting, this is the first I've heard of it literally burning out. A one off, I could believe. The fact that this one electrician is having this many fail, in my mind, implies they are doing something wrong.

I agreed, but can't figure out what they are doing wrong. Appropriate gauge black wire, appropriate gauge not-black wire, appropriate gauge copper wire all attached at the proper locations in the fcsp and the appropriate as size circuit breaker. Then tighten to proper torque. There isn't much to screw up.

 

[TaxmanHog]

Then tighten to proper torque.

Miscalibrated torque wrench ???????

Placing to much stress on the PCB causing board failures

 

[phxdonald]

I agreed, but can't figure out what they are doing wrong. Appropriate gauge black wire, appropriate gauge not-black wire, appropriate gauge copper wire all attached at the proper locations in the fcsp and the appropriate as size circuit breaker. Then tighten to proper torque. There isn't much to screw up.

AGree. I even heard from our local Ford dealer that they have "had problems".

 

[Henry Ford]

AGree. I even heard from our local Ford dealer that they have "had problems".

Anecdotally, the FCSP "problems" that are reported on forums are failure to connect and faults solved by a software upgrade, which is kind of the same problem. I keep a pretty close eye on the two biggest Lightning forums and yours is the second instance I recall of a legit dead FCSP.

If there's a was major problem with FCSPs it would be all over the forums. Every time someone's tailgate doesn't close the first time it's a new thread.

 

[Labs4Lightning]

Anecdotally, the FCSP "problems" that are reported on forums are failure to connect and faults solved by a software upgrade, which is kind of the same problem. I keep a pretty close eye on the two biggest Lightning forums and yours is the second instance I recall of a legit dead FCSP.

If there's a was major problem with FCSPs it would be all over the forums. Every time someone's tailgate doesn't close the first time it's a new thread.

@Henry Ford anecdotally faults that can be corrected by firmware upgrade, hmm that’s broad & inaccurate.

so under your hypothesis I should be able update my firmware and my daily fault will go away. Interesting I’ve had CSP since August, updated firmware as available but I have charging fault with no description every time I charge for the past 2 weeks. Doesn’t appear to be the common .64 heat tolerance as within a minute it has attained full charging rate. So having the latest firmware where do I find the firmware you reference to rid my CSP of faulting?
so no not all faults can be solved by a firmware upgrade.

my comments are light hearted for comical reading for all those post where people don’t want to do any homework - not a personal attack on your post.

i don’t see a new daily post for tailgate not closing - I do see ”my update failed 3 times, anyone else have this problem?”

i also you search function to Research similar problems before creating a new post.

 

[Henry Ford]

@Henry Ford anecdotally faults that can be corrected by firmware upgrade, hmm that’s broad & inaccurate.

so under your hypothesis I should be able update my firmware and my daily fault will go away. Interesting I’ve had CSP since August, updated firmware as available but I have charging fault with no description every time I charge for the past 2 weeks. Doesn’t appear to be the common .64 heat tolerance as within a minute it has attained full charging rate. So having the latest firmware where do I find the firmware you reference to rid my CSP of faulting?
so no not all faults can be solved by a firmware upgrade.

my comments are light hearted for comical reading for all those post where people don’t want to do any homework - not a personal attack on your post.

i don’t see a new daily post for tailgate not closing - I do see ”my update failed 3 times, anyone else have this problem?”

i also you search function to Research similar problems before creating a new post.

I wasn't suggesting your issue could be solved by a software update, I was suggesting your issue wasn't common. The fact that in six weeks no one has responded to a post in which I called your issue the "second instance I recall of a legit dead FCSP" suggests I was correct.

 

[Dolmans]

@Henry Ford anecdotally faults that can be corrected by firmware upgrade, hmm that’s broad & inaccurate.

so under your hypothesis I should be able update my firmware and my daily fault will go away. Interesting I’ve had CSP since August, updated firmware as available but I have charging fault with no description every time I charge for the past 2 weeks. Doesn’t appear to be the common .64 heat tolerance as within a minute it has attained full charging rate. So having the latest firmware where do I find the firmware you reference to rid my CSP of faulting?
so no not all faults can be solved by a firmware upgrade.

my comments are light hearted for comical reading for all those post where people don’t want to do any homework - not a personal attack on your post.

i don’t see a new daily post for tailgate not closing - I do see ”my update failed 3 times, anyone else have this problem?”

i also you search function to Research similar problems before creating a new post.

My Ford Charge Station Pro worked fine for about 3 weeks (two Charges) and now has the following fault. The station has experienced a non-recoverable fault. This explanation is from the installation Guide. Which is the result of a solid red LED Status on the charger as soon as it's plugged into the Lightning. After 10 days of waiting for this 2.112.87 update Ford is shipping a new charger today.

 

[The Weatherman]

My Ford Charge Station Pro worked fine for about 3 weeks (two Charges) and now has the following fault. The station has experienced a non-recoverable fault. This explanation is from the installation Guide. Which is the result of a solid red LED Status on the charger as soon as it's plugged into the Lightning. After 10 days of waiting for this 2.112.87 update Ford is shipping a new charger today.

I have had mine installed since May, so ~3 months, and I started getting a small right hand side yellow fault periodically throughout the charging session. According to the manual it is a fault that requires diagnosing.

Today I rolled the charge rate back to 64AMPS and was able to charge the few minutes I needed to get back 90% without it wigging out.

I’m not too confident it will solve the problem, but I thought I’ld give it a shot before getting FORD support involved.

Seems these chargers are definitely a weak link.

 

[DucMan]

Mine has the “yellow light on the right side“ fault now. I called ford, they had me try to reset it by powering down/ up. I had already tried that. Didn’t change anything. they have “opened a ticket” and will get back to me. It worked well since November…

Scott

Sponsored