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Issue with Level 2 charger randomly stopping ?

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#121 ·
lmcancu said:
loose connection between your EVSE and the car charge port? Do the pins look charred? What EVSE do you use?
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I have tried on different evse with same results, its a problem with the car, seems like the few folks that have had it remediated successfully by Hyundai have had the charge port assembly/wiring harness replaced.
 
#122 ·
upa said:
I originally thought these charge session disconnects were related to a faulty temperature sensor unfortunately I have now come to the conclusion there is definitely something wrong with the car's AC inlet connection/wiring. It can't handle anything above 42 amps. At 48 amps or 11.3KW and 20C ambient I just logged the car's AC inlet temperature sensor rise in about 20 minutes to 100C of 212F before it disconnected from the EVSE. The j1772 connector and car's CCS AC port were hot to touch. If the car's AC inlet temp sensor were to fail its quite possible this would be a fire risk. I can see this being a recall issue eventually.
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I agree with this assessment. I started charging at 48amps before the issues started. First I dropped the EVSE down to 40A and that seemed to work. Then that started failing so I adjusted the charge setting on the car to reduced. That worked, but just last night it failed. The J1772 port and connector get really hot. I have to think it's a problem with the cars inverter.

I have an appointment with the dealer, will update when they take a look at it.
 
#124 ·
upa said:
I have tried on different evse with same results, its a problem with the car, seems like the few folks that have had it remediated successfully by Hyundai have had the charge port assembly/wiring harness replaced.
Click to expand...
Ok so in late June when I got the Ioniq five I initially had some stop charging 20 minutes or half hour into the charge with EVSE. I have a 240 that is linked to the charge cord with a 20 foot extension. I had gone into the car infotainment screen and clicked on the upper left icon. That’s the one with the leaf (EV). Then to the settings wheel icon on the far right In the next screen. Lower row. In there I switched to medium from high. It takes only an extra hour maybe so five hours instead of four to go from 20% to 80%. The initial reading on the charge cord would go to 42 A and it would cut off . Now it goes to no more than 38 A and I have not had a problem since. We have had extremely warm temperatures above 100d. for weeks. The charge cord I use is actually considered a portable one. The brand is Lectron. No problems at portable chargers either, using fast chargers.
 
#125 ·
upa said:
I originally thought these charge session disconnects were related to a faulty temperature sensor unfortunately I have now come to the conclusion there is definitely something wrong with the car's AC inlet connection/wiring. It can't handle anything above 42 amps. At 48 amps or 11.3KW and 20C ambient I just logged the car's AC inlet temperature sensor rise in about 20 minutes to 100C of 212F before it disconnected from the EVSE. The j1772 connector and car's CCS AC port were hot to touch. If the car's AC inlet temp sensor were to fail its quite possible this would be a fire risk. I can see this being a recall issue eventually.

View attachment 45250
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Which scanner are you using?
 
#130 · (Edited)
jjd said:
My Ioniq 5 is only two weeks old, so this might not be that useful a data point, but I have a ChargePoint Home Flex hardwired with a 60A breaker and the few times I've charged (at 11.6kW) in temps in the 80s and 90s (New England) there hasn't been a problem charging to 90%. 🤞 (This is inside my non air conditioned garage.)
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Update: This has started happening to me -- randomly stopping charge even when I5 is on "Reduced" charging setting. I had to set the charging rate to "Minimum" in order to complete charging. (6.6kw instead of ~11 kw)

This even happens when the garage temperature is in the 70s (Fahrenheit).
 
#131 ·
This also just started happening to me after using my hardwired Chargepoint without issues for ~3 months. On my charging activity panel in the CP app, it says "Fully Charged" after it added 12 kWh to bring it up to 71% despite the AC charging limit being set to 90%. This was on an overnight charge (not hot out at all). And it's been doing this for a few days now, only adding around 11-12 kWh and then stopping, "randomly".

I'll try setting to minimum charging rate too, and making calls to Chargepoint and Hyundai; really hoping this gets figured out ASAP!
 
#132 ·
I’ve had my ioniq for nearly 3 months (all summer) since June. No problems charging at 48A ever until 2-3 weeks ago. That happened to be the time I took it in for its first service at my local dealer. Coincidentally, temps have been very high locally in that same time period.

(1) temp problem? (Weather)
(2) updated software/firmware problem?
(3) combination of both?
(4) part initially working and failed after 3 months?

Don’t know which of those is at play.

I can say for sure that my hardwired 48A charger is not the problem and it never overheated anything for 3 months. The ionic charged fine at 48A many times. No disconnects. Not even once. And we had weeks here and there over the last 3 months over 95F and even 100F. Charged previously without any issues. Last 3 weeks have been terrible.
 
#133 ·
Lotsofyoda said:
I’ve had my ioniq for nearly 3 months (all summer) since June. No problems charging at 48A ever until 2-3 weeks ago. That happened to be the time I took it in for its first service at my local dealer. Coincidentally, temps have been very high locally in that same time period.

(1) temp problem? (Weather)
(2) updated software/firmware problem?
(3) combination of both?
(4) part initially working and failed after 3 months?

Don’t know which of those is at play.

I can say for sure that my hardwired 48A charger is not the problem and it never overheated anything for 3 months. The ionic charged fine at 48A many times. No disconnects. Not even once. And we had weeks here and there over the last 3 months over 95F and even 100F. Charged previously without any issues. Last 3 weeks have been terrible.
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Ambient temperature can definitely exacerbate the problem, but I truly believe the problem is that the car's internal AC to DC converter had been insufficiently designed to handle the higher currents and is over heating. This is why reducing amps alleviates this problem. This is why Lv1 and DCFC does not have this problem (well DCFC can have other issues). This is why when we have cooler weather, people did not see this problem as much.

I'd be interested to see if this issue goes away in the MY23s if Hyundai beefs up the converter to reduce AC impedance.
 
#134 ·
I just watched Korean YouTube and he is kind of Korean version of Sandy Munro. He recently tear down motors and some parts for ioniq5/ev6. He said stop charging/slow charging issue (with heat) can be ICCU. His suggestion was checking ICCU from the dealer then if the dealer find the faulty ICCU then replace it. If the dealer did not find ICCU issue then just use the car until ICCU stops to work since the car has the warranty.
 
#135 ·
Lotsofyoda said:
I’ve had my ioniq for nearly 3 months (all summer) since June. No problems charging at 48A ever until 2-3 weeks ago. That happened to be the time I took it in for its first service at my local dealer. Coincidentally, temps have been very high locally in that same time period.

(1) temp problem? (Weather)
(2) updated software/firmware problem?
(3) combination of both?
(4) part initially working and failed after 3 months?

Don’t know which of those is at play.

I can say for sure that my hardwired 48A charger is not the problem and it never overheated anything for 3 months. The ionic charged fine at 48A many times. No disconnects. Not even once. And we had weeks here and there over the last 3 months over 95F and even 100F. Charged previously without any issues. Last 3 weeks have been terrible.
Click to expand...
I believe its the charge port over heating due to ambient air temp. Have to lower the charge rate, it supposedly helps
 
#136 ·
Yes. Update.
Dropping to 32A worked to charge at the high outdoor temps in the 90s and above.
Today our outside temp dropped to the high 70s and I was able to increase my charge amps back up to 48A on my charger. No problem with disconnects at all. Charged fine at full blast.
 
#138 ·
kimguroo said:
I just watched Korean YouTube and he is kind of Korean version of Sandy Munro. He recently tear down motors and some parts for ioniq5/ev6. He said stop charging/slow charging issue (with heat) can be ICCU. His suggestion was checking ICCU from the dealer then if the dealer find the faulty ICCU then replace it. If the dealer did not find ICCU issue then just use the car until ICCU stops to work since the car has the warranty.
Click to expand...
What is ICCU? When I took my car to the dealer, they couldn't replicate the problem on their level 2 charger because it only does 6.6kW. They said the solution was to set the limit to 100%, haha total BS.
 
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