Weird Charging Issue -- Possibly after module replacement

[TaxmanHog]

@TaxmanHog Would you agree that I am on the right track and 18.5% is way out of spec?

Short of knowing the procedures and limitations, I humbly think this is well outside what is intended.

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[AntJohn73]

I agree. It is pretty damn close to a 20% variance which would explain why the current is ramping down so drastically at 80%.

 

[electricpig]

I agree. It is pretty damn close to a 20% variance which would explain why the current is ramping down so drastically at 80%.

For reference, here is my SOC and Voltage variation a couple of days ago. 0 Voltage and 0.28% SOC variation.

 

[AntJohn73]

Thanks! Yeah, 18.5% variation is way out of spec!

 

[ctuan13]

I am having a similar issue after Module replacement. I got mine back on Dec 23rd and have cycled the battery a few times. Every time it charges back to about 65% then soc jumps to 100% and it's done (no balancing happening).

My module soc variation was about 16% via car scanner, now up to almost 19%. Bad module or balanced incorrectly, either way I'm taking it back in on Monday.

I'm assuming you've tried a 12V reset? (Disconnecting the negative terminal of the 12V battery for at least 5 minutes and then reconnecting) Give it a try, you've got nothing to lose.

I've never needed a module replaced (knock on wood) but I've suffered a deep discharge event where two summers ago on a cross country road trip, I ran completely out in South Dakota and coasted to a stop on the side of the highway. Upon recharging the battery, everything seemed okay at first. But over the next couple weeks the battery module SOC variation and voltage variation continued to creep upward until it culminated two weeks after when upon arriving in Washinton state the battery percentage dropped from something like 32% to 20% in like 20 minutes of just sitting parked and "idling". Then when I rushed to the nearest charger like 4 miles away, I watched the percentage drop steadily every minute, until right before pulling up to the charger, I swear it dropped a percent a second. I plugged into the charger, with the IP reading something like 12%.

Fearing the worst, I resigned myself to the belief that I must have damaged the battery with my deep discharge and I would need a module replacement. But with nothing to lose, I figured, I'd try a 12V reset which in the past had fixed a glitch with SOC readings. After reconnecting the 12V battery, within 3-4 key cycles, the module voltage variance was down to 0.01V and the SOC variance was down to 0.5%. (At its worst, voltage variation got to 0.03V and SOC variation got to just under 6%)

Give it a try and let us know if it makes any difference!

 

[AntJohn73]

Yeah, it can't hurt at this point. I will try it this morning.

 

[Grumpy2]

Do you have access to a better more experienced Dealer?

I believe Ford sends a replacement battery module with about 50% charge. You didn't charge beyond 80% for a period of time so perhaps you are still working on the original balancing that the dealer failed to do ???

 

[AntJohn73]

I believe that is exactly what is going on here. I will give them a shot and explain the issue on the 14th.

 

[Ford Motor Company]

I believe that is exactly what is going on here. I will give them a shot and explain the issue on the 14th.

Playing catch up here, but I will send this to some folks on my end and get their POV. I'll need your VIN for them to look at the vehicle data - I'll message you.

 

[Mpi]

@Ford Motor Company Ping me as well if you want a second example.

 

[AntJohn73]

I did the 12V reset just to be sure. It is still at about 18.7% variance.

 

[LiteNing]

Playing catch up here, but I will send this to some folks on my end and get their POV. I'll need your VIN for them to look at the vehicle data - I'll message you.

@Ford Motor Company ping me for a third example.

 

[Mpi]

I have one interesting observation from yesterday. I plugged into an 80A tesla wall charger at work. My truck charged normally to 59% displayed, then it dropped to ~1.1kwh and appeared to be working on balancing for the next four hours before I hade to unplug to go home. SOC variation did drop very slightly, ~.1%, in that time (from 18.9% to 18.8%). When I go home I plugged into my basic 16A/240V EVSE and it charged straight to 63% before jumping to 100% and quitting as it has since the module replacement.

The charger at work is underground where it was about 10 degrees Celsius (~50F), but it is also much more powerful than my home EVSE. Which of these differences made it start to work on balancing I cannot be sure. My truck is at the dealership this morning and I will follow up with what they say.

One question: OP's EVSE indicated balancing in progress. Can I see that indicator somewhere with Carscanner Pro?

 

[Firn]

20% variation this many months later isnt proper. I suspect this isnt from your original module replacement but instead is from something else (another bad module perhaps).

I wonder if a solid fast charge session would trigger a CEL

 

[Mpi]

My dealer has confirmed a full balancing is needed. The service rep told me the original instructions from Ford were to balance the new module to match the battery. Now Ford tells them a more involved balancing is needed where each module, new and old, will be balanced and the voltage set to some common level before reinstallation. I'm not sure how accurate all that is, but it's what I'm told.

So such a condition as we've been discussing does exist, and it won't necessarily throw a wrench light or brick the truck. If you are aware enough of your vehicle this should be a good thing.

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