Charging error (All 5 segments turn RED) HVB Module failure

[Piquette]

Sounds like they are having to reprogram parts of the charging system to accommodate the new charging port parts. This can sometimes take many hours of a tech’s time.

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[chl]

finally got the charger port at dealer took truck in yesterday. said it would take 3 hours. took car in at 12pm came back at 4:30pm and they said it will take at least another 4 hours. so we had to leave it and they will call on Monday when finished. at least they offered to bring it to our house, which I 83 miles away.

I was told those pins are for DCFC top portion is for AC and communication. however I did not design or research this just took their word.

Yes the pins on the truck are for DC charging he battery directly, but they are NOT energized (connected to the battery) unless you are hooked up to a Fast DC charger when internal contacts are engaged to make the connection under control of the on-board software system designed with electrical safety in mind.

So, as far as I know, they are not a danger of shock unless you somehow touched them during a Fast DC charging cycle - which would be hard to do since the plug or adapter is supposed to lock to prevent premature withdrawal and the arcing that could result, and the pins are recessed on the truck.

The charging software communication protocol handles the requests and responses for the on-off of the DC fast charging connection, and there is a button you can push to end the charging as well (next to the CCS1 plug socket).

I read about a couple fast charger shock incidents, very rare,, but I believe they were when a maintenance person was working on them and made a fatal mistake - electricity can be unforgiving.

Obviously if the charge station looks like it has been damaged don't use it. But battery fires during fast charging are more of a risk than electric shock, and they are rare as well. And most of those incidents were Tesla's.

https://www.researchgate.net/figure...ctric-vehicles-in-recent-years_tbl1_355228230

Of course, not having the truck DC pins covered could lead to other problems eventually if water got down in there and corroded them.

The one thing never to touch would be the pins on the DC charger itself!

I there was a fault they could be energized before plugging in to the vehicle receptacle - unlikely but...

 

[doggod]

finally got my truck back only took them 5 days to replace the port. replaced my USB ports in front, they stopped working. I also see the replaced the battery tray? and recharged the AC?

not able to touch the DCFC pins on charger when they are powered up as they have to be plugged in to activate and unable to unplug without being powered off.

Dealer said it could lead to plug not fitting properly. to me that means could short out and cause fire

 

[Heliian]

read about a couple fast charger shock incidents, very rare,,

I have never heard of anyone being shocked by a dcfc but anything is possible. If you know of any links, I'd love to read.

 

[chl]

I have never heard of anyone being shocked by a dcfc but anything is possible. If you know of any links, I'd love to read.

I shared them in another post a while back, maybe in March 2025, not sure if I saved them on my PC, but I'll look.

One was a contractor working on a Tesla charger as I recall who didn't take adequate precautions to avoid electrocution....

Googled Tesla charger death and found these two, one is still not determined if the charger was involved, the second in Norfolk was the one I read about before:

31-year-old man was found dead inside a Tesla at a supercharger station in San Antonio, according to MySA. The cause of death is pending.

In an unrelated incident, a worker was killed at a Tesla Supercharger in Norfolk while doing installation work, and the cause of death is still under investigation, but may have been electrocution, according to WTKR


Details of the Norfolk incident:

• A worker was found dead at a Supercharger station during installation work.
• The cause of death is still under investigation, but police suspect electrocution.
• The Supercharger was scheduled to open the following day.
  

There have been other cases of shocks felt but no death when using L2 EVSEs.

I think I found them after someone on another forum asked about the warning on the Tesla adapter insert about not using it when water or snow is present - here is a pic of the warning and if you got your adapter you can see it.

So I looked for any info about the possibility of injury or death from that scenario.

By the way, the Tesla mobile power charger apparently has a warning about rain:

"Warning: If rain falls during charging, do not allow rain water to run along the length of charge cable, causing the electrical outlet or charging port to..."

One study purportedly found that water incursion was possible with a CCS type 2 which could cause trouble including shorts and shocks, even “rapid unscheduled disassembly” of a plug...but we use type 1 though so maybe the problem is limited to type 2? Also that was in a Reddit post so I guess take it with a grain of salt since who knows if it is accurate or true, but FWIW it said:
---
I am working for a EV OEM and we have not had any cases och electric shocks on vehicles during charging during development. ( We started developing EVs in 2012).

We have however had cases of water intrusion in the charging plug (CCS type 2) causing shortcircuit and plug exploding which in its turn caused pieces of the plug flying.

Luckaly nobody got injured in these three instances since nobody stood near the charging vehicle.

Root cause for the fault is production faults in plug water proofing (different suppliers in all three cases).

It was also concluded that the CCS standard could be improved so that the PE pin is moved above DC pins so that the isolation measurement device in the EVSE could detect isolation drop due to water intrusion. Tesla standard and MCS already have that implemented.
----
Of course, if there is any malfunction in the DCFC equipment, given the high voltages and current, things could get ugly. Hopefully they are well maintained, But have to watch out in case they have been vandalized or damaged and avoid those that have (duh?).

L2 with 240V and up to 80A has to be treated with respect as well. Installation, damage to cords or wiring, damage to J1772 plugs, etc. all could lead to a shock.

There was one case I read about where someone had not fully seated the 240V dongle of a Ford Mobile Power Cord and got a mild shock from it. That could also lead to a fire from the higher resistance connection if the plug or socket pins become corroded, for example.

Not saying this happens a lot. Anything with electricity should be handled responsibly with due care, even a light bulb. Most of the time a 120V household shock won't kill you, but there are exceptions.

People smoke at gas stations and do other careless things with ICE vehicles, lawn mowers, bar-b-ques, as well.

Hope I didn't stir up a hornets nest here...time will tell.

 

[chl]

I charge my Lightning in my driveway, my FCSP is inside the garage, the cord passes through a RV pass-through door and up to a hanger so that when plugged in, the cord has a drip loop so any rain will not flow either into the truck CCS1 port of back inside the garage.

I also place a plastic wrap over the charge port when plugged in if rain is possible to keep it dry.

But I am a generally cautious person when it comes to electricity, EVs and my home.

 

[LightningJB]

Ford might cover the rental if either
1- You have a Ford Extended Warranty with 1st day rental coverage that you paid for
2- They agreed to it front
3- You get the BEV team to agree to it.

My recent Lightning purchase was at a local dealership that provides FREE loaners for only customer's that bought vehicles from them. They picked up my Lightning and delivered a Brand New 2025 Expedition last week when I needed service. I was only responsible to give it back with the same Full Fuel as it was delivered with.

I just returned from Jack Madden service after a wasted trip. The tech on the phone said it was ready - and when I got there it was not. I will have to start a new thread for the full report - I am still out of service with a hope for having the truck back tomorrow if no other problems appear. I understand that they are limited by lack of technicians but their lack of urgency and support for a customer that bought the truck at their dealership is astounding.

 

[ctuan13]

That's been an acronym since cars were differentiated by model year. See also FY - fiscal year, CY - calendar year, and AY - assessment year.

And of course CYA (Cover Your Ass)

 

[TaxmanHog]

I just returned from Jack Madden service after a wasted trip. The tech on the phone said it was ready - and when I got there it was not. I will have to start a new thread for the full report - I am still out of service with a hope for having the truck back tomorrow if no other problems appear. I understand that they are limited by lack of technicians but their lack of urgency and support for a customer that bought the truck at their dealership is astounding.

You can continue sharing on this thread, but if you like, I could partition all your posts here to a unique thread, let me know.

 

[LightningJB]

I just returned from Jack Madden service after a wasted trip. The tech on the phone said it was ready - and when I got there it was not. I will have to start a new thread for the full report - I am still out of service with a hope for having the truck back tomorrow if no other problems appear. I understand that they are limited by lack of technicians but their lack of urgency and support for a customer that bought the truck at their dealership is astounding.

I am going to paste the timeline as captured in text messaging. No editorial comments as the content speaks for itself. I will report back tomorrow, hopefully for the last time when I get the truck back.

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