Charge Station Pro Problems

[ChrisCon]

My CSP is connected on the 5ghz frequency. Just a heads up for anyone using Eero, advanced security settings appeared to block it from connecting to the internet in the beginning.

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[Fast911]

I hooked up my CSP inside the garage over the weekend and the weather was in the 100 degrees outside. I set the truck to charge to 100% and the charger stopped at 97%. I was unable to get the ford pass app, ford charging station pro app to sync with my WiFi. I tried for 2 days and like others, I get the “wrong password”, so unknown if there are any charging messages that everyone is getting. The charger stayed pulsing blue while charging and I never got an solid amber light. I used #2 wiring. Definitely something wrong with the ford charger, I never had so much problem trying to connect something to WiFi. I got like 3 bars on the phone and iPad but all I get is the dreaded ” wrong password”.

 

[O’Majestic1’slightnigF150]

Need to replace the rain bird with a Rachio.

 

[tls]

The FCSP is a required component to the home integration system. There is no way to get the DC from the truck to a bi-directional inverter without it. They may end up selling it only with the home integration system or via their web site.

Frankly, I think they just need to add some quality to it.

There is the very similar Delta BiDi unit I accidentally found which is not Ford branded and comes with its own CCS cable directly connected to the inverter housing (I posted the datasheet a couple of months ago when I had it confused with the model Ford is using) I haven't yet figured out If that's a real product or vapor, but it would sidestep the need to use the FCSP for AC charging...

 

[Griddlez]

I hooked up my CSP inside the garage over the weekend and the weather was in the 100 degrees outside. I set the truck to charge to 100% and the charger stopped at 97%. I was unable to get the ford pass app, ford charging station pro app to sync with my WiFi. I tried for 2 days and like others, I get the “wrong password”, so unknown if there are any charging messages that everyone is getting. The charger stayed pulsing blue while charging and I never got an solid amber light. I used #2 wiring. Definitely something wrong with the ford charger, I never had so much problem trying to connect something to WiFi. I got like 3 bars on the phone and iPad but all I get is the dreaded ” wrong password”.

It stopped, like it won't work any more, dead?

 

[Fast911]

It stopped, like it won't work any more, dead?

no…it just stopped charging at 97%. I disconnected the charger from the truck and the light is blue on the charger ready to charge again.

 

[PiMatrix]

Smaller conductors used inside the unit generate some heat due to resistance (for example, Tesla uses 105 degC #6 for its 80A cabling). The contactor coils get energized and generate some heat holding them closed while the vehicle is charging. The control electronics generate some heat as well. It's not a lot of heat, but in a closed chassis it builds up, in conjunction with higher ambient temps.



I've seen high-quality items from Siemens, and I've seen them produce some utter crap. And I should note that some real crap out there has gotten UL certification before.

I will see if I have an 80A issue when I get this installed tomorrow night / Sunday morning.

Caveat: I have no proof this is absolute cause of issue other than something this important should be done to spec or it could overheat. Someone else will have to verify.

So I finally opened the box for the FCSP just to look around and see how it worked. Since I don't have a truck yet I can't test anything but I decided to check one thing that might cause the design to overheat with 80A vs a lower current. The wire going to the truck is of a lower gauge (#6) but still requires at least 35 ft-lbs and perhaps it's not torqued to spec making a higher resistance connection. Without a temp gauge or heat map from IR camera or probe I can't really say for sure but this sort of thing has always been an issue in panel boxes with loose connections causing heat build up (or worse).

I put my hex torque wrench the two power feeds to the truck inside the FCSP just to check and found ~25 ft-lbs vs the spec 35 ft-lb minimum on ONE of the TWO hot wires. The ground was fine. I don't think an electrical installer would go back and check Siemens work so this might not be caught if an manuf plant assembly error.

I've attached a video. The other two wires to the Lightning were to spec 35 ft-lb. Note the installer wires must be torqued to 60 ft-lbs for 3 gauge but that is up to electrician installer to do.

So just a hypothesis, after shutting the mains breaker you might check the green blue brown wires going to the lightning and see if they are not torqued to spec or seem loose. Best if you have a torque wrench, mine only goes down to 37 but I believe it was torqued to something around 25 ft-lbs and seemed somewhat loose when I turned it unlike the other two (hot and ground).

Turn off power first and only do if you are comfortable with it. The hex size is 5/32 or 4mm. If someone is having a lot of shutdowns the wire when pulled out could be a bit coated with copper oxide residue from the high heat IF this is cause. This is an issue that will get continually worse with time as residue builds up and thermal stress loosening so if that is what you are seeing it would be consistent.

Can someone curious give this a try and let us know if wire is loose and if so does it remove the issue after tightening? It would be better to have IR camera temp map beforehand so this is a shot in dark. If this is cause firmware would not be reliable fix. On other hand maybe the design can tolerate an under-torqued power feed but it should absolutely be to spec. So at the very least have your electrician check those connections.

Here is video of blue wire that seems in-spec torque >35 ft-lb:

Here is video of the brown wire that seems somewhat loose and out of spec <25-27 ft-lb.

 

[CTBob]

We know some of our customers using the Charge Station Pro are getting error messages on FordPass while charging. We plan to push an over-the-air (OTA) update in the coming days to rectify the issue. To ensure this OTA update is successful, customers should ensure their Charge Station Pro is connected to their home WiFi.

Customers can continue to use their Charge Station Pro in the meantime. Thanks for flagging with us and for your patience while we get the OTA update out to your charger.

I would like to be able to down OTA update, but I cannot connect my Pro to Ford Pass as I do not have a password. Only think on the sticker on my charger is an Access Code, What do you advise? Thanks

 

[FlasherZ]

I would like to be able to down OTA update, but I cannot connect my Pro to Ford Pass as I do not have a password. Only think on the sticker on my charger is an Access Code, What do you advise? Thanks

The access code is the password. Download the app called "Ford Charge Station Pro Setup" by Siemens, and it will help step you through the process. Whenever you're asked for the station's password, the access code will be used.

 

[Griddlez]

Have we had anyone say, confidently that the pro charger works with other cars? I can say mine does.

Got it installed today and am currently charging our Mach-E with it. Hopefully my truck shows up later this week to do full 80 amp testing. Believe the Mach-E is capping out around 48 but hard to say with the ford pass software.

Oh and the wireless setup and ford pass account connection/setup worked the first time for me. No need to reset anything.

 

[Gimme_my_MME]

Have we had anyone say, confidently that the pro charger works with other cars? I can say mine does.

Got it installed today and am currently charging our Mach-E with it. Hopefully my truck shows up later this week to do full 80 amp testing. Believe the Mach-E is capping out around 48 but hard to say with the ford pass software.

Oh and the wireless setup and ford pass account connection/setup worked the first time for me. No need to reset anything.

You might actually have a unicorn

 

[FlasherZ]

Have we had anyone say, confidently that the pro charger works with other cars? I can say mine does.

Got it installed today and am currently charging our Mach-E with it. Hopefully my truck shows up later this week to do full 80 amp testing. Believe the Mach-E is capping out around 48 but hard to say with the ford pass software.

Oh and the wireless setup and ford pass account connection/setup worked the first time for me. No need to reset anything.

The Mach-E only charges at 48A, and most peoples' FCSPs are working at 64A without shutting down.

 

[Com@]

We know some of our customers using the Charge Station Pro are getting error messages on FordPass while charging. We plan to push an over-the-air (OTA) update in the coming days to rectify the issue. To ensure this OTA update is successful, customers should ensure their Charge Station Pro is connected to their home WiFi.

Customers can continue to use their Charge Station Pro in the meantime. Thanks for flagging with us and for your patience while we get the OTA update out to your charger.

Hey @Ford Motor Company, what firmware version should include this fix??? I'm running the FCSP at 60A waiting a fix!

 

[RainorshinePNW]

Even at 60 amps I was still getting 1 notification of an error/reset over the course of a multi hour charge period. However last night I charged with the grey plastic cover OFF and it charged for 5+ hours without an error. Fingers crossed, could be a fluke, but seems like a good sign.

 

[idahospud]

Today my electrician completed the install of the Pro 80 amp charger while I was at work. When I came home, I attempted to "pair" to the unit unsuccessfully for about an hour. I stopped using the Ford Connected Charge Station app (as suggested with the inbox directions) and attempted to connect though the Ford Pass app - that process worked (unit went into pairing mode as evidenced by flashing "white" bar on front of unit and connected to wifi). Although the box is connected to wifi I have not successfully linked the unit to the the ford pass app yet (to many attempts - retry in 15 Minutes). Also, it is 103 degrees in in my town today, my garage is in the upper 90's. The unit has been charging for while with no overheat issues yet - fingers crossed!

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