Charge Station Pro Overheating and restarting issues

[Mashedtators]

I had the same issue and when I dialed it back in the app it worked perfectly. 60amps is not an issue and I’m ok with that given all the headaches I had installing it. 80amps generates a weird noise and the charger eventually faults. I’m not sure what software version I’m on though.

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[Maquis]

Will need to keep calling them I believe. Currently they are saying that overheating is normal.

Mine doesn’t.

 

[MaintGrl]

Over heating is NOT normal. Provided you have the right gauge of wire for the amperage & run and breaker, If this persists, I would have to say the Charge Station Pro has problems that Ford needs to address.

 

[dodgedak]

Over heating is NOT normal. Provided you have the right gauge of wire for the amperage & run and breaker, If this persists, I would have to say the Charge Station Pro has problems that Ford needs to address.

I agree. We used #3 copper cable and 100 amp breaker.
I measured the temperature today on the charger and near the pulsing blue light of the charger it measured approx 114 F at peak temperature and the charging cable measured max 99F, this was when it was delivering 17kw charge rate to the vehicle. Since the ambient temperature was 77F i think it didn't throw any overheating message. If it was 100F ambient outside it probably will.

 

[MFT]

I had the same issue about a year ago and indeed it turned out to be a faulty FCSP in my case. They sent me a new one and swapped it out. Haven't had an issue since. Good luck

 

[Danface]

The install requires #2 copper, it would run hotter with #3

 

[FANTIEPEI1]

Still could be wiring. May want to have your electrician double check everything it torqued correctly.Both under and over torqued connections can cause overheating. If all to spec then I push back on Ford to get a replacement.

I agree I’m willing to bet it’s not torqued down to the specs in the manual. Before I had mine installed I found a thread about the over heating issue because wiring wasn’t torqued to spec. I had to tell my licensed electrician that he needed to torque to spec he wasn’t planning on it till I mentioned it. I have no over heating issues currently

 

[THX1138]

I recently had the FCSP installed with a 100 amp breaker and a 25 feet run with the #3 wires by a licensed electrician and it is installed inside the garage.
First day when it started charging it was shutting down and restarting multiple times. I contacted support and they mentioned I had an older firmware .64 and had to have the new .91 firmware installed to avoid the overheating issue and the quickest way to do this was to reset the circuit breaker which I did and was able to get the .91 firmware. After this I thought the problem would go away but it has only reduced the number of restarts, charger charges at 16 or 17Kw rate for approx 50-55 minutes and then it restarts and again ramps up to 17kw. I called the ford BEV support and they say it is operating fine, as long as it does not stop charging ignore the restart messages and it should continue to finish the charge. Also suggested placing a pedestal fan next to charger so that it does not overheat. Which seems preposterous. If temp was the issue i tried charging early morning when the temp was in the 60's and still the same issue. Any thoughts/feedback ?.
I have yet to derate it to 72 or 64 amps by turning the setting from 7 to 6 or 5, will have the try that. But the main purpose of spending money to install this was to get the full rate but Ford is not helping by saying this is a normal behavior.
edited: to update actual breaker amp. It is a 100 amp breaker.

Wild thought here, ask you electrician to look at the wire going into it at the screw terminals. Ask the electrician to unscrew the terminals and look at the wires, to make sure the strands are intact and not sheared from the screw terminals pinching the wire.

I suspect the bottom the the screw terminals are concave and shear strands of the terminal wire. $0.02.

 

[Maquis]

The install requires #2 copper, it would run hotter with #3

That’s completely wrong. The requirement is for a 100A branch circuit, which corresponds to #3 unless there is some unusual derating involved. The terminals on the FCSP are rated for #3 max.

 

[Danface]

That’s completely wrong. The requirement is for a 100A branch circuit, which corresponds to #3 unless there is some unusual derating involved. The terminals on the FCSP are rated for #3 max.

You're right. I installed an 80 amp commercial version (based on the Liteon EX-1193) similar to the Ford commercial one which required #2 wire. Thank you for the correction. BTW, I used #2 for the Ford Pro I installed at our place in Maine so way overkill especially for a 7 ft run. Thanks again!!

 

[TaxmanHog]

You're right. I installed an 80 amp commercial version (based on the Liteon EX-1193) similar to the Ford commercial one which required #2 wire. Thank you for the correction. BTW, I used #2 for the Ford Pro I installed at our place in Maine so way overkill especially for a 7 ft run. Thanks again!!

Microsoft Word - US-1P80A gen2_USER_Manual_v1_ 20230418 (base 0222)_POS (fcc.report)

 

[Danface]

Microsoft Word - US-1P80A gen2_USER_Manual_v1_ 20230418 (base 0222)_POS (fcc.report)

 

[Danface]

Bingo! Funny how the same input/ouptut chargers have different requirements. The run for the EX-1193 is about 65 ft. When I get some time I want to play around with getting the OCPP info from the InCharge one.

 

[dodgedak]

I agree I’m willing to bet it’s not torqued down to the specs in the manual. Before I had mine installed I found a thread about the over heating issue because wiring wasn’t torqued to spec. I had to tell my licensed electrician that he needed to torque to spec he wasn’t planning on it till I mentioned it. I have no over heating issues currently

Electrician will be here this wednesday to check the torque, it is probably not torqued like you mentioned.

 

[NJAdales2]

After charging without issue to 80% from 30-60% a couple of times a week from late Feb. until mid-May, our FCSP started to have the charge interrupted ("charging error") for a few minutes and then to restart, building back up to the usual 16.7 kW, and then stopping with the error message, over and over. The FCSP showed an amber light instead of blue when in "error" state. In troubleshooting, we discovered that our home network could not detect the FCSP. Called Ford and BEV customer service agent could tell from our unit # that we had not received the necessary firmware update. After a couple of tries, the FCSP still did not get the update. She said she'd escalate this in the tech chain and the next day, she texted to report that our FCSP had been approved for replacement and that a new unit would be shipped to us. When I said I assumed Ford would reimburse us for what we'll have to pay our electrician to remove the defective unit and install the new one, she said she'd "review the options for reimbursement" and give me an update in a couple of days, by Friday, 6/14. No word yet. She said it is safe to use the charger as we have been in the meantime. I'm pleased with the responsiveness of Ford folks, but not so much with the FCSP as it was used lightly only a few months.

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