Ford Mobile Charger Internal View

carys98 · Jul 16, 2024

Someone on the MachE Facebook page posted some photos of the inside of the mobile charger. Their charger failed so they cut it open to see if they could identify the problem. Apparently the unit is sealed and cannot be opened without destroying the case.

Ford F-150 Lightning Ford Mobile Charger Internal View IMG_0467

Maxx · Jul 16, 2024

Interesting to see. Thanks for sharing.

Mine overheats and de-rate itself to a lower current and keeps fluctuating. I just stopped using it. If someone told they had the same problem and problem was a component like this, I would open up and try to fix it.

Ford F-150 Lightning Ford Mobile Charger Internal View 1721151767654-dh

But if it is one of those chips, I wouldn't bother.

Heliian · Jul 16, 2024

Maxx said:
Interesting to see. Thanks for sharing.

Mine overheats and de-rate itself to a lower current and keeps fluctuating. I just stopped using it. If someone told they had the same problem and problem was a component like this, I would open up and try to fix it.

But if it is one of those chips, I wouldn't bother.

I would try a new 240v dongle before opening it up.

Maxx · Jul 16, 2024

Heliian said:
I would try a new 240v dongle before opening it up.

Never thought of that. I did lose the neutral to my house a while back which screwed up a few pieces of electronics. I suspect, that may have messed up one of the components in there but you suggestion makes sense. I will check it when I see my cousin that has a mustang. Thanks.

chl · Jul 17, 2024

carys98 said:
Someone on the MachE Facebook page posted some photos of the inside of the mobile charger. Their charger failed so they cut it open to see if they could identify the problem. Apparently the unit is sealed and cannot be opened without destroying the case.

Interesting. Been several postings of failures of these over time by people using them daily, one where there was a nearby lightning strike that may have cause a surge current/voltage to the unit.

chl · Jul 17, 2024

Maxx said:
Never thought of that. I did lose the neutral to my house a while back which screwed up a few pieces of electronics. I suspect, that may have messed up one of the components in there but you suggestion makes sense. I will check it when I see my cousin that has a mustang. Thanks.

Doesn't use the neutral, just 2 hot and ground, I traced the wiring myself through the dongle.
The neutral pin is N/C.

But if the outlet was wired wrong, and the neutral was lifted (not connected to ground at the main service panel, then maybe...

Ford F-150 Lightning Ford Mobile Charger Internal View Mobile Power Cord-240v dongle-2

Also, if HOT 2 were disconnected, the AC to DC converter in the Lightning would detect 120V between HOT 1 and GND, and perhaps function as an L1 would.

Ford F-150 Lightning Ford Mobile Charger Internal View Mobile Power Cord-120v dongle

Assuming a split phase converter:

Ford F-150 Lightning Ford Mobile Charger Internal View split phase full wave rectifier-J1772 pins

Like the above.

marc_hanna · Jul 17, 2024

Here’s the insides of one that I built back in 2013.

Ford F-150 Lightning Ford Mobile Charger Internal View IMG_7031

chl · Jul 17, 2024

Maxx said:
Interesting to see. Thanks for sharing.

Mine overheats and de-rate itself to a lower current and keeps fluctuating. I just stopped using it. If someone told they had the same problem and problem was a component like this, I would open up and try to fix it.

But if it is one of those chips, I wouldn't bother.

Three pin circuit board devices are usually transistors (triode).

We know this is a Webasto Go EVSE from the circuit board marking and other information.

Looking it up, I could not as yet locate a circuit diagram, but the item is available on Amazon:

https://www.amazon.com/Webasto-Dual-Voltage-Portable-Charger/dp/B0BTK7WPLZ

32% gave it 1 star on Amazon!
Lots of failures!

chl · Jul 17, 2024

marc_hanna said:
Here’s the insides of one that I built back in 2013.

Was this a kit, and if so from whom?
I remember open EV had some kits...

marc_hanna · Jul 17, 2024

No. I built this from scratch. Searched out retail components from all over. The controller was a self-assemble from OpenEVSE. It didn’t come assembled with preloaded software back then. Now the controller only costs $150, whereas I just bought a brand new complete 32 amp charging station for $119. Over time, I decided to add the LCD display and then reset switch, and ultimately an additional 240vac outlet on the side. The whole thing cost me about $160CAD for a 32 amp unit. At the time, comparable units were selling for $1,000 or more.

tkittlitz · Jul 17, 2024

Mine got water in it while charging one day after it had rained. It started malfunctioning and giving me a red light error all the time. I took the adapter out - filled with alcohol, let it drain and dry in a warm dry area. It has worked great ever since. Just posting this in case other people have the same problem if charger got wet inside.

Mike G · Jul 20, 2024

I still have three of the Ford portables....one still brand new in the plastic. I will only use one in a very extreme emergency now. The routine overheating got pretty stupid. Like 14-15hrs to go from 55% back up to 90? Ridiculous.

I mounted a Wallbox 48A as a replacement and couldn't be happier.

Mike G · Jul 20, 2024

Was there any failure analysis to go along with that FB post? Like does he know why it failed at all?

wighty · Jul 28, 2024

Maxx said:
Mine overheats and de-rate itself to a lower current and keeps fluctuating. I just stopped using it

My understanding is it would be covered under the 3 year/36 month warranty... did you ask about it?

Maxx · Jul 28, 2024

wighty said:
My understanding is it would be covered under the 3 year/36 month warranty... did you ask about it?

My truck is a 23 and I did not suppose to get one. I got it with a bit of arm twisting ( dealer took it off another truck on the lot). Didn't want to push my lock, but I doubt I have anything to lose. I may give it a shot.

Ford Mobile Charger Internal View

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