Battery overheating? during drive and charging

[lmlaster]

7/4/2019
Summer recently arrived here in Chicago.

Recently I am getting lots of charging faults. The car will not complete the charging cycle, sends me a text stating
"NWI White Lightning had a fault while charging"
5 minutes later I'll get another
"NWI White Lightning's scheduled charge has not begun"

I go out to the garage and a very loud fan is running in the engine. AC???

Driving on a hot day with 20+ miles, I also get the orange wrench and the orange battery on the dash. Sounds to me like the battery is overheating. We don't have many EVs here, Our local Ford tech is submitting a warrantee to Ford to replace a cable. Sounds like he's way off.

Any suggestions? or links


2015 FFE - "NWI White Lightning"

 

[mdfocus]

Check coolant level.
Have dealer do a coolant system purge. Ask them to do it twice. This will get rid of any air trapped in system and if one of the coolant valve are not working it should show up while they are doing the procedure.

Hope this helps.

 

[lmlaster]

Update
7/5 Ford replaced my 110 charger under warrantee. It was causing a charging fault while the dealers charger worked fine. I never use this charger. I have a 220 in the garage.
While the car is sitting in front of the dealer. More warning lights go on. Back home in the loaner.
It’s about 90 outside.

7/10/19
Got a TEXT from my Ford mobile at 5:55 am “..scheduled charge has not begun”
Last night, the tech had taken the car home (20+ miles) to try to reproduce the problem.
When he returned to the shop in the morning, he plugged in from 5:49-6:18

Ford dealer called. My free loaner time has expired. Back to the dealer.
I convince the service writer the problem will be recreated, as it is 95 outside.
The car has a message: “It’s hot outside, plug in when you’re not driving”
(Plug in to cool it down??)
I drive the car 3 miles at 50+ and the battery and wrench warning lights go on.
Back to the dealer. The car is still sitting, running with the AC running and I get 3 texts in the next 10 minutes:
3:57 “…scheduled charge has not begun”
4:06 “… has a warning light on”
4:07 “… has a warning light on”

This has stumped a seasoned Ford technician. Fortunately, he has a ticket open with Ford. Hopefully, they can figure it out. Driving our ¾ ton truck is not good.

 

[Heima]

Not to be snarky, but your seasoned Ford Tech has or has not pulled codes from the vehicle?
You might want to consider looking at my post from the other day about "Something to Check on Your Car".
It could be that you have a similar problem with a falsely secured HV connector. Maybe not the one in the photos.
Maybe your problem is that the connector that carries the temperature signal is not properly connected.

 

[lmlaster]

He pulled the codes. Has Ford assisting. I have one of very few (3??) in NW INdiana. These techs don't see the EVs often. Hopefully he saw your reply.
They are charging the car and getting errors as we speak. Its 95 again here.

Thanks

 

[lmlaster]

July 24
The service manager offered me a free loaner. Great option. I really just want the car back and to function properly.

While there, they had the car charging using the brand new 110 charger replaced under warrantee. It was charging in the shop using an extension cord. Not recommended.

Today 10:46 I got a text from the FFE: NWI White Lightnings scheduled charge has not begun.
When I looked at My Ford Mobile app, it shows the car charged from 4:00-4:48. I need to find out when they actually plugged it in.

My car has the following codes
u019B - 3 times Lost communication?
U0100
U0111
U3003 - voltage issue

I read some ford Hybrid issues that if the 12 volt had low voltage the solenoid would not work properly. If that happens in a FFE, could the coolant not be getting to the HV battery?

Day 24 and counting

 

[Heima]

My car has the following codes
u019B <- HS CAN communication lost between BECM and SOBDM while battery was charging, could be a connector.
U0100 <- HS CAN communication lost between BECM and PCM, vehicle will not start, could be a connector.
U0111 <- HS CAN communication lost between BECM and GFM2, could be a connector.
U3003 <- BECM detects voltage either less than 8.5 or greater than 16 Check fuse 11 in the rear junction box.

Do we see a trend here?
If I was fixing the car, I would first check the connectors on the BECM (upper battery pack) particularly C4805E (The big connector under the battery cover)
Connector C4805E pins of interest
Pin 7,20 - CAN BUS HS HIGH
Pin 9 - CTRL MOD- WAKE UP PCM FROM BECM
Pin 12,16 - CAN BUS HS LOW
Pin 14 - 12V POWER SUPPLY OUTPUT
Pin 15,19 - FUSE 11 or CIRCUIT BREAKER
Pin 22 - TEMPERATURE OUTPUT SIGNAL
Pin 23- TEMPERATURE INPUT SIGNAL
Pin 26- TEMPERATURE INPUT SIGNAL RETURN
Pin 33- TEMPERATURE OUTPUT SIGNAL RETURN

 

[lmlaster]

Wow. That’s a lot of detai.
Are you a Ford tech or engineer?