Receiving charging error on my FordPro charger.

[matthew.theoret34]

Receiving charging error from my FordPro charger.

it happens just about every time. Someone’s it will start up again.
Other times it will stop charging.
I reset the breaker and plug it back in and will start to charge again.
Not ideal as I plug it in overnight for my shift in the morning.
Charger shows a solid yellow light on the right side of the charger light bar.
Any advice?
Charger is from 2023

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[TaxmanHog]

What kind of temperatures are you experiencing, hopefully it's not a heat induced derating, a fully patched FCSP with current firmware is less likely to prematurely derate because of charging current + environmental heat, it's still possible though.

The yellow bar to the right means the rate of charge (amps) is reduced, you should look at the [CHARGE STATION] function at the bottom of the energy tab, review the settings, look at the "Max Charge Current", if it's showing less the 80 amps adjust it higher, while not charging, once the change has posted power cycle the FCSP to see if that causes the yellow light to shut off.

Also look at the pin's of the J1772 portion of the cable and the port on the truck, any oddly positioned pins or sockets?

 

[Heliian]

If everything is up to date and it still shows yellow you'll probably have to turn power off and retorque the wire connections in your evse installation.

 

[chl]

Some owners seem to have had trouble with the charge port on the truck leading to FCSP error messages or worse - popped breakers in the house.

Maybe the connector pins and sockets get corroded or wires somewhere in the port come loose, haven't seen any explanation of what goes wrong with the port.

Does this happen at/with other L2 chargers? If so it's likely the port on your Lightning.

If not, could be loose wires in the FCSP plug/cord/inside or even loose power supply wiring to the FCSP - they have been known to come loose and cause errors too.

Good luck figuring it out. By process of elimination (e.g., trying the truck with another L2 EVSE) you should be able to get to the bottom of it.

 

[matthew.theoret34]

Thanks for the reply. No, it only happens with this charger

 

[matthew.theoret34]

What kind of temperatures are you experiencing, hopefully it's not a heat induced derating, a fully patched FCSP with current firmware is less likely to prematurely derate because of charging current + environmental heat, it's still possible though.

The yellow bar to the right means the rate of charge (amps) is reduced, you should look at the [CHARGE STATION] function at the bottom of the energy tab, review the settings, look at the "Max Charge Current", if it's showing less the 80 amps adjust it higher, while not charging, once the change has posted power cycle the FCSP to see if that causes the yellow light to shut off.

Also look at the pin's of the J1772 portion of the cable and the port on the truck, any oddly positioned pins or sockets?

It’s been crazy hot. I’m wondering if that’s it.

 

[matthew.theoret34]

If everything is up to date and it still shows yellow you'll probably have to turn power off and retorque the wire connections in your evse installation.

Okay, I’ll maybe give that a try.

 

[chl]

Some owners seem to have had trouble with the charge port on the truck leading to FCSP error messages or worse - popped breakers in the house.

Maybe the connector pins and sockets get corroded or wires somewhere in the port come loose, haven't seen any explanation of what goes wrong with the port.

Does this happen at/with other L2 chargers? If so it's likely the port on your Lightning.

If not, could be loose wires in the FCSP plug/cord/inside or even loose power supply wiring to the FCSP - they have been known to come loose and cause errors too.

Good luck figuring it out. By process of elimination (e.g., trying the truck with another L2 EVSE) you should be able to get to the bottom of it.

OK, that's the good news.

Now, what's causing the FCSP troubles could be one of a few things:

1) Sometimes the power wires come loose inside the FCSP - to fix that, power off at the breaker, open FCSP (9 or so T20 torx head screws) and then test the terminals with a 240VAC voltmeter to be sure there is no voltage!!!

Then with a torque screwdriver tighten the terminal screws/lugs to the recommended torque (I believe they are a small 5/32" hex - something is 9/16" hex but I don;t recall if it's those or something else):

a) the hots (usually red and black could be 2 blacks or a black and a white) tighten to 60 in-lbs (6.8 NM) and

b) the green ground wire tighten to 35 in-lbs (4 NM).

If you don't have a torque driver then better call an electrician with one - the torque is critical.
The torque specified in the install manual above assumes an 80A install with #3 and #6 wire. Torque for smaller wire is not specified, but an electrician should know what the correct torque is.

2) sometimes the wires come loose in your breaker box. Call an electrician if tightening the FCSP lugs didn't do the trick, so he can check and tighten the Breaker screws - torque is critical - and how much to torque there depends on the specification from the breaker maker for the wire size you are using.

3) Anything else I'd say call for warranty repair/replacement. There have been a few that needed to be replaced under warranty (3 years I believe). If your CCS1 cord or plug have an issue, not much you can do on your own.

Probably other folks will give you similar advice to the above in less detail perhaps.

I attach the install manual FYI.

Good luck.

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