Charge Station Pro issues - in the most unlikely way

[Wjburgin]

All:

I intended to post this a few weeks ago when I initially had an issue with a Red fault light on my Charge Station Pro. At the time, the unit was immediately jumping to red when I plugged my truck into the charger. I could reset the CSP by cycling the breaker, but the problem was persistent. I consulted this forum to see if there were other issues such as mine - while none were exactly my problem, I tried a few suggestions anyway.

When that didn't work I called the installing electrician. We were shocked (not literally) when water poured out of the CSP upon opening! Because my truck won't fit into my garage, I mounted the unit just outside on the garage wall. The electrical connections go through the wall into conduit, the CSP is rated for outdoor service, and while the unit is exposed to rain directly, it's not in any "high flow" areas like downspouts or the like. I have no idea how the water got in.

Having removed the water, the unit began operating normally, until last night. When the electricians "repaired" it last time, they caulked the wires coming in the rear, the joints of the CSP itself, and the gap between the back and the wall. So, imagine my surprise when I opened the unit and more water - albeit less than before - came running out! The error this time was a yellow light - "Charging Error". I'm wondering if the moist environment has corroded some of the electronics inside the CSP and that's what is now causing the problem. When the sun is up, I'll open the CSP so it can more fully dry and I can see if there is anything obvious.

Not only am I interested if you have ever heard of such, but I'm also wondering if you think that Ford will warranty the unit, as I did have it professionally installed. Also, if I were to buy something other than a CSP, what would you recommend? CNET likes the TESLSA charger. The CSP is on a 60-amp breaker charging at 48 amps - so I'd want that much capacity again.

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[CD4TNF]

That's incredible that the FCSP isn't weatherproof. Wow.


The 48 amp or more chargers I'm aware of are:

Enphase is the old reliable ClipperCreek style. Goes up to 64 amps.
https://enphase.com/ev-chargers/home


Grizzl-E, goes up to 80 amps. Canadian, so might be an issue with tariffs.
https://grizzl-e.com/products/grizzl-e-ultimate/


ChargePoint, 50 amps.

https://www.chargepoint.com/drivers/home


Wallbox Pulsar Plus goes up to 48 amps.
https://wallbox.com/en_us/pulsar-plus-ev-charger

 

[Heliian]

caulked the wires coming in the rear,

If it's installed properly with proper connections then there is no need for caulking.

It's 100% an installation issue. Many people, myself included, have them mounted outside.

There is also a gasket on the cover and a torque sequence listed in the install manual.

 

[sfringer]

I'll agree with @Heliian, this sounds like an install issue. My FCSP has been mounted outside on the side of my garage and functioning without issue for nearly two years. It's weathered heavy rain, snow, ice.

 

[Maquis]

That's incredible that the FCSP isn't weatherproof. Wow.

It is waterproof. The water has to be coming in either where the conduit enters the unit or through the conduit itself.

 

[jefrank]

1) Installation issue (as others have said), or
2) Defective unit with bad weather-sealing?

 

[chl]

Definitely an installer/installation issue.
I assume the installer had the installation guide.

NOTE: it sounds like your installation may not be correct because you say "When the electricians "repaired" it last time, they caulked the wires coming in the rear." You also mentioned conduit.
The rear entry is NOT for conduit, so if that is where the conduit enters, without a gang box, that is a mistake. The rear entry is for when mounting on a wall with a gang box at the rear of the FCSP.

The conduit MUST enter from the sides:

Also the guide mentions this for outdoor/exterior mounting:

However, if the conduit goes to a gang box at the rear of the unit, that would be acceptable.

Judging from what you said about water pouring out, that seem like a water leak through the conduit either at the back or some where up the line from the FCSP along the conduit route.

If water were just leaking in through the case gaskets around the edges, I would not expect a large quantity of water to be present unless the FCSP was submersed under water.

So you probably need get your electrical contractor (or a different one?) back to do it right if it was not to spec.

Not to spec would mean the warranty would not be enforceable/applicable.

---
This reminds me of a story from the Island of Montserrat where a volcano sent many tradesmen into exile in the UK and the US in the 1990's.

Down there, they run wires through PVC conduit.
They also run the water lines through PVC conduit.

When someone I know as renovating a home there, they found that whenever they ran the shower, water would leak from the kitchen ceiling fixture.

Yes, you guessed it, the water line conduit to the shower head had been connected somehow to the electrical conduit to the kitchen light!

They do use different types of conduit for electrical and water there, but they are the same color - white - and someone got them mixed up.

Like a Three Stooges episode.

 

[djwildstar]

We were shocked (not literally) when water poured out of the CSP upon opening! Because my truck won't fit into my garage, I mounted the unit just outside on the garage wall. The electrical connections go through the wall into conduit, the CSP is rated for outdoor service, and while the unit is exposed to rain directly, it's not in any "high flow" areas like downspouts or the like.

Properly installed, the FCSP is rated NEMA Type IV, "Waterproof":

• Suitable for indoor and outdoor use including construction sites, docks, and tunnels.
• Protects against the ingress of water including rain, sleet, and snow.
• Protects against the ingress of dust, falling dirt, and windblown dust.
• Will not be damaged by ice forming on the enclosure.
• Protects against hose-directed water from a 1-inch hose at 65 gallons per minute.

That last bullet is essentially a 1-inch fire hose at full pressure. Type IV enclosures are often used at dairies, breweries, and other locations where cleaning workers regularly wash the facility down with a hose. You should literally be able to mount it directly under a downspout and not have a problem.

Since you're getting water inside, either the case is damaged or it isn't properly installed.

From your description, I'm guessing it isn't properly installed. For residential wiring rear entry (page 12 of the installation guide), there shouldn't be any holes drilled through the charger case; instead, they should be pierced through the supplied rear plug.

The other possibility is that the gasket that seals the case is missing, damaged, or dislodged from the cover. This is fairly easy to do, and page 16 of the installation guide asks that the installer verify the gasket is still present and correctly seated when closing the unit up.

Mine has been installed on the outside of the house for nearly 2 years with no problems. The electricians ran conduit in via conduit on the lower-left side of the charger. Th is has an exposed conduit run from near the garage door around the corner of the house where the charger is installed.

 

[Henry Ford]

The other possibility is that the gasket that seals the case is missing, damaged, or dislodged from the cover.

The gasket is there because it's keeping the water in.

@Wjburgin, post some photos. Someone here will be able to tell you what the problem is.

 

[djwildstar]

The gasket is there because it's keeping the water in.

Heh, true -- though a gap in the top of the gasket could let water in without having it leak out.

I agree with the other posters, though: the most likely is either that water is getting in the back (if the electricians either didn't use or damaged the rear-entry fitting) or is getting into conduit at some other location and filling the charger from the inside.

 

[Maquis]

Heh, true -- though a gap in the top of the gasket could let water in without having it leak out.

I agree with the other posters, though: the most likely is either that water is getting in the back (if the electricians either didn't use or damaged the rear-entry fitting) or is getting into conduit at some other location and filling the charger from the inside.

To add - every conduit run outdoors gets some amount of water in it unless you live in an arid climate. If nothing else due to condensation. If the FCSP is the low point of the run, water will collect there.

 

[Tony Burgh]

I agree with djwildsta.
Per installation manual
INSTALLATION LOCATION
Between 35″ and 60″ from ground to device midpoint.
NEMA 4 waterproofing for outdoor or indoor installation.

My FCSP is mounted on the north wall of integral garage.
Power wireing in conduit enters the rear of the box
It has been hit with water from garden hose when washing vehicles.
Never found any trace of moisture inside.

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