Blowing breaker on home charger setup.

[mattwils77]

Hi all, having an issue with blowing the breaker (twice now) on my new home charger set up.

2024 Flash ER
Pion Flex-AC elite 7.2kw 6-32A charger
40A circuit breaker
Max draw on charger set at 24A (auto set, I cannot adjust).
im also using a 15ft 50A rv extension cord as my charger cord isn’t long enough.

I just had a module replaced in the battery and the truck has charged no problem on the dealers chargers.

has anyone had any similar issues with this charger or setup?

going to have the electrician load test the circuit to ensure it’s not got an issue like a faulty breaker or something.

thanks!

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[RickLightning]

Assuming you have the Ford Mobile Charger, plug it in. If it works, you have identified the problem.

I would suggest then eliminating the extension cord if possible to see if that's the issue, even if that isn't an ideal setup.

Ideally, you should not be using an extension cord.

 

[Maquis]

What is the actual charge rate (shown in FordPass)? It shouldn't be over about 5.5 KW. If that’s correct, the problem is at the breaker - excess heat due to either loose wiring connections or breaker to bus connection.

ETA: There is nothing else connected to this circuit, correct?

 

[garsh]

What kind of outlet are you using? NEMA 14-50?
The EVSE itself can go up to 32 amps.
A (properly-installed) 40-amp circuit should be able to deliver 32 amps continuous (80% rule).

Max draw on charger set at 24A (auto set, I cannot adjust).

Does this mean that the truck itself is limiting the draw to 24 amps? If so, it might be detecting a voltage drop larger than it likes. And that could very well be due to your use of an extension cord.

going to have the electrician load test the circuit to ensure it’s not got an issue like a faulty breaker or something.

That's good. Something doesn't seem to be adding up here.

 

[PJnc284]

I would also have them ensure the 14/50 outlet isn't an el-cheapo. It could be in the first stages of going poof and tripping the breaker.

 

[RLXXI]

My money is on the extension cord.

 

[mattwils77]

All good suggestions thanks! It’s the charger limiting to 24A not the truck.
Electrician says the type of breaker I have is a bit notorious for not being great so he’ll come load test and replace the breaker. I’ll also try without extension cord to see how it goes.

 

[chriserx]

Out of curiosity what breaker is it. I'm assuming that it's not a GFCI tripping, but I also assume that the need for an extension cord means it's outside which would mean that GFCI is required. I tried looking up the specs but the site keeps crashing (appears to be detecting my dark mode but infinitely looping) for me but the one on Amazon didn't appear to have GFCI built in. Can you confirm whether it's a breaker trip or GFCI? Also can you confirm there are no other devices on that circuit? And finally, can you check the voltages on the legs? Maybe the loads on the panel are imbalanced? Unlikely at that power draw but still worth a look. I can't look up the manual to know the conditions for the charger to be auto set at 24A but it implies it doesn't like something.

 

[mattwils77]

Out of curiosity what breaker is it. I'm assuming that it's not a GFCI tripping, but I also assume that the need for an extension cord means it's outside which would mean that GFCI is required. I tried looking up the specs but the site keeps crashing (appears to be detecting my dark mode but infinitely looping) for me but the one on Amazon didn't appear to have GFCI built in. Can you confirm whether it's a breaker trip or GFCI? Also can you confirm there are no other devices on that circuit? And finally, can you check the voltages on the legs? Maybe the loads on the panel are imbalanced? Unlikely at that power draw but still worth a look. I can't look up the manual to know the conditions for the charger to be auto set at 24A but it implies it doesn't like something.

it’s a federal pioneer breaker. Regular breaker not gfci.

currently charging the truck and hasn’t tripped yet this time so we’ll see how it goes…….

 

[chriserx]

If it does it again you can try to reseat the breaker, but it does appear to be a bad design so I wouldn't get my hopes up.

 

[Maquis]

it’s a federal pioneer breaker. Regular breaker not gfci.

currently charging the truck and hasn’t tripped yet this time so we’ll see how it goes…….

Federal Pacific? Never heard of Federal Pioneer.

Some older FP breakers are problematic, as your electrician alluded to. But the failure mode is normally that they never trip and burn the house down. The opposite of your problem.

 

[Heliian]

Federal Pioneer.

It's the Canadian branch of federal pacific.

 

[Maquis]

It's the Canadian branch of federal pacific.

Learned something new! Thanks.

 

[kibo]

Just in case you're unaware, most plug-in EVSEs have temperature sensors built into the plug. The sensor detects if the connection at the wall outlet is overheating (due to a high resistance connection at the plug or outlet). If the outlet overheats, the EVSE will throw a fault and shut off.

When you use an extension cord, the sensor is no longer detecting the temperature at the wall outlet and you lose this protection.

 

[WillGrey1907]

Federal Pacific? Never heard of Federal Pioneer.

Some older FP breakers are problematic, as your electrician alluded to. But the failure mode is normally that they never trip and burn the house down. The opposite of your problem.

I had significant issues with Federal Pacific (house is from the late 1950s) and once I had an electrician replace the entire panel I've had no issues with charging (60A circuit) or other. I use the Ford supplied Emporia wall charger at 48A.

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