Weird Charging Issue -- Possibly after module replacement

[AntJohn73]

@Sealevel Thanks for the info. Does your L2 charger have a readout like mine does? I would like to see at what point the charge current drops. Thanks

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[Sealevel]

@Sealevel Thanks for the info. Does your L2 charger have a readout like mine does? I would like to see at what point the charge current drops. Thanks

Sorry, I have a Grizzl-E basic. All I can see is average over time on the Ford App.

 

[AntJohn73]

OK thanks1

 

[mr.Magoo]

I haven't had any of my modules replaced, but here's a curve from 20 - 100% on a L2 (40A setting) charger. As you can see the current/power doesn't really change/drop until 98.8% (98.5% if I zoom in for more granular data / every 15s)

 

[AntJohn73]

@mr.Magoo Thank you. I knew something was wrong. What is your temperature where you live? It has been cold as hell here in New Jersey. It has been between 15 and 20 degrees here!

 

[mr.Magoo]

@mr.Magoo Thank you. I knew something was wrong. What is your temperature where you live? It has been cold as hell here in New Jersey. It has been between 15 and 20 degrees here!

That was from September so not cold by any means.

The battery will naturally warm up during charging even if it's not being actively heated (on L2), so usually by the time you reach 80-90% SoC, the battery is 40+ degrees even with 20 degree weather like it is here in Michigan right now, so it wouldn't be throttling at the end of the charge cycle due to it bring cold.


Here's a 20-80% from 2 days ago

 

[mr.Magoo]

With an OBD plug and carscanner/torque app (as others have suggested) you can look at these values and get an understanding as to what's going on.

You can see (for example) actual power vs requested, that'll tell you if its the truck asking for less at the end, or, if perhaps something is up with your charger.

You can also look at the balance between the different modules, both SoC and voltage.

It's an inexpensive investment to gain more knowledge about your vehicle.

 

[PJnc284]

Car Scanner for reference

 

[TaxmanHog]

One thing to remember about the taper profile, I agree that a 'healthy' battery pack will show the current slowing after 98% on a level 2 charging EVSE at 80 amp and lower capacities.

But it's possible Ford has programmed the BMS to behave more cautiously when one module is substantially out of calibration to the rest of the original pack, cautiously slowing the charging rate should resolve once all modules are in alignment, 22 days was the stated time frame, yet the OP had work done in October, so at this point 60+ days have elapsed, why hasn't the battery reached a balanced condition by now?

New years eve charging back to 90%, note the last hour by the minute approaching 90%

 

[Wendy]

I also have a 23 Lariat ER, and one of the things you mentioned I noticed. On a trip to the great white north, temps between 0°F and 28. I fast charged to 90% (I don’t see any way to go beyond that, no slider showing when I Fast Charge), and as soon as we were moving and I glanced down I saw it was at 85%. My thought is the cold temperature messes with the SOC calculations. Based upon the usage of ~60% of the SOC on that leg of the trip I believe it actually did get to 90%.

 

[AntJohn73]

@TaxmanHog Yes, I remember that it used to taper down after 90%. I am going to monitor it closely over the weekend. I do have an appointment for January 14th at the dealer.

 

[dandeliongo]

How many of you guys have had modules replaced??? And how long did it take to get? Mine has been in the shop for a week with NO ETA for my replacement.

 

[LiteNing]

Thanks for all of the replies. Yes, it does reach 100% but it drops down right after the truck is "started". I believe they properly balanced the modules after #9 was installed. There are no codes at this point.

This (and I mean all the symptoms you described here) is very similar to what I am observing in the thread over here. If you get a Bluetooth OBD dongle, the free app (you pay to remove ads) Car Scanner can directly show your cell state of charge imbalance as well as the difference in average a minimum cell voltage.

I also had two modules replaced about 9 months ago. I noticed the first symptoms about 2-2.5 months ago but it took a while before I realized what was happening.

 

[LiteNing]

But it's possible Ford has programmed the BMS to behave more cautiously when one module is substantially out of calibration to the rest of the original pack, cautiously slowing the charging rate should resolve once all modules are in alignment, 22 days was the stated time frame, yet the OP had work done in October, so at this point 60+ days have elapsed, why hasn't the battery reached a balanced condition by now?

I wonder if the BMS software is incapable of balancing the modules when they are grossly out of balance. Some BMSes only top balance under certain conditions, and it’s possible those conditions are never met when the imbalance exceeds some threshold..

For example: If one module reaches the charge stop voltage when the others are still at 90-92%, is the BMS smart enough to hold the pack voltage constant while the other modules catch up? Or does that one module at stop voltage simply abort the charge session and thus prevent balancing?

Over xmas I repeatedly charged to 100% on L1 at my in-laws, hoping to trigger the balance logic. The SOC imbalance reported by Car Scanner has not improved, nor has average-min cell voltage.

Here’s another data point that I observed (repeatably): Charge to 100% displayed SOC (i.e., charge to 92% then watch it jump to 100). Leave it plugged in. Use the remote start to run the heater for 2x 15 minute sessions. Watch SOC drop to 91%.

In this condition, charging will not start and will not recharge to 100%. I forgot to screenshot it, but the app shows “starting charge” indefinitely (at least several hours) and SOC displayed remains at 91%.

However, if I get in and start the truck (while still plugged in) to get it down to ~90%, it will recharge back to 92% and jump to 100% again.

I’m eager to see what AntJohn’s dealer says about warranty coverage because I’d to get this addressed on mine.

 

[Sealevel]

How many of you guys have had modules replaced??? And how long did it take to get? Mine has been in the shop for a week with NO ETA for my replacement.

I forget which member of the forum has a tracking spreadsheet for module replacement, my work was initiated in June and took about 7 weeks from diagnosis through replacement. I drove Blue Mule for 4+ weeks with the diminished charge level (67%) and the dealership worked on it for 2+ weeks. Mine was the first they had done and there were delays for missing instructions (including a special tool needed) and waiting for parts.

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