Charge to 100% on L2 charger, but GOM shows 84% on startup

[frautumn]

How would one know if they have this problem if they only charge to 50 or 60 percent regularly? I only charge above 75 if I am going on a long trip (truck is usually driven locally a few days per week).

I would have never known if I didn't charge above 70. When I charged to 80, it slowed down significantly around 77% or so, which was noticeable so that would be how I would have figured something was wrong if I had only been charging to 80. There were no errors or malfunctions of any kind reported.

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[TaxmanHog]

There were no errors or malfunctions of any kind reported.

That is very odd that no errors were triggered, so many reports of module failures usually resulting in reduced motor energy, then tripping the code and subsequently restricted charging.

 

[GoodSam]

Got my Lightning back today, they replaced Module #9 (on warranty of course). My previous module replacement (March 2023) was Module #8. I wonder how many others have had more than 1 replaced??

See my spreadsheet in my signature below and look for the red highlighted lines...too many! You are now included.

 

[CD4TNF]

Good work @GoodSam! That's quite a tracking sheet you have going.

 

[Texas Dan]

Just got word back from the dealer and it looks like my Lightning has an array (module) failure. It’s going to a week for delivery of the parts and a couple of more days to install and test. Okay, somebody tell me what’s the difference between a module and an array? My service writer was really struggling with that question and didn’t seem to know what a module was.

 

[CD4TNF]

Here's a short vid on replacing the Lightning's battery module.




Somewhere the answer is likely in Munro's battery teardown.

 

[Firn]

How would one know if they have this problem if they only charge to 50 or 60 percent regularly? I only charge above 75 if I am going on a long trip (truck is usually driven locally a few days per week).

It's recomended to charge to 100% on occasion, and it would answer this question for you. There is no harm in charging to 100% once in a while.

In your case charge it up to 100% the night before you are going to do some driving, that way it isn't sitting for multiple days at 100%. Be warned though, it takes many hours to go from 99% to 100%, so make sure you give it enough time.

 

[VTbuckeye]

It's recomended to charge to 100% on occasion, and it would answer this question for you. There is no harm in charging to 100% once in a while.

In your case charge it up to 100% the night before you are going to do some driving, that way it isn't sitting for multiple days at 100%. Be warned though, it takes many hours to go from 99% to 100%, so make sure you give it enough time.

Yes, I am aware of how long it takes. I have no reticence when it comes to charging to 100 percent when traveling, but there is no need to leave the truck at a high state of charge regularly. It probably goes to 100 quarterly and has been into the single digits once.

 

[Firn]

Yes, I am aware of how long it takes. I have no reticence when it comes to charging to 100 percent when traveling, but there is no need to leave the truck at a high state of charge regularly. It probably goes to 100 quarterly and has been into the single digits once.

Then I would say there is nothing to worry about. Provided you do in fact charge to 100% on occasion then if this very rare situation happens then you will find out. For those that never go to 100% charge, and are worried of this, then the recommendation would be to charge to 100% on occasion, but it seems like you already do that. There would be no need to keep it at 100%, or to charge to 100% frequently, just for this rare issue (IMO).

 

[frautumn]

Okay, somebody tell me what’s the difference between a module and an array?

Not sure I've heard it called an "array" before, but I'm assuming they are just using a different word for module.

Each truck has ONE battery pack
Which contains 9 modules
Each module contains many cels (20 or 30 ish I think).

If a cel goes bad, they have to replace the module that contains that cel. Presumably they send that module back to the factory where the good cels can be separated and used in refurbished modules.

I'm no expert on this so somebody can correct me if I'm wrong.

 

[TaxmanHog]

If a cel goes bad, they have to replace the module that contains that cel. Presumably they send that module back to the factory where the good cels can be separated and used in refurbished modules.

I'm no expert on this so somebody can correct me if I'm wrong.

I believe the defective module is sent for study of failure, then destructive reclamation of minerals

 

[GoodSam]

Not sure I've heard it called an "array" before, but I'm assuming they are just using a different word for module.
Each truck has ONE battery pack
Which contains 9 modules
Each module contains many cels (20 or 30 ish I think).

See this link to @Ford Senior Master post on the # of cells and types of modules and various combinations.
https://www.f150lightningforum.com/...dules-starting-with-chatgpt.21142/post-488187

I thought that array might refer to a battery pack of the 9 modules, but not sure how @Ford Motor Company uses the word in this post below--I am thinking array=pack, not one of the 9 modules.
https://www.f150lightningforum.com/...-high-voltage-battery-cells.25351/post-487796

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