Charging complaints - Initial analysis
Topic number

LI54.10-P-055824

Version

1

Design group

54.10 Battery, voltage supply, voltage converter

Date

03-05-2013

Validity

451ev3 (smart electric drive 3rd generation) as of VIN
end no. 581474

Reason for change
Reason for block

Complaint:
•
•
•
•
•

Charging inoperative
Charging abortion
Fault messages (flash codes) on charging cable box (ICCU or Intelligent Charging Control Unit)
Fault messages (flash codes) on charging socket on vehicle
Question/problems associated with charging process

Cause:

In principle, faults during the charging process and charging abortions can have different reasons. These include:
•
•
•
•
•

Infrastructure
Charging cable with box (ICCU)
Charging socket
On-board charger (OBL)
HV battery or vehicle control (internal)

For an exact fault analysis and fault rectification please note the points raised in the Remedy chapter with attachments in the TIPS document.
In each instance, it is essential that the customer complaint and the basic conditions are asked about at the
customer's (in particular, which charging mode/charging cable/charger was used) and the customer's charging infrastructure should also be examined.

Remedy:

A) A flash code with red LED on the charging cable box (ICCU) is shown
After inserting the charging cable a self-test is run first. If, after this, one of the two upper LEDs (AC LED and/or CCICLED) lights up in red or if they flash on and off, a malfunction is present.
=> Please use Attachments A1+A2 in this TIPS document to help with interpretation of the possible reasons for the
charging fault and die flash codes.
=> Rectify the fault in accordance with the details given in "Remedy/recommended actions" in the attachment.
B) A flash code on the vehicle's charging socket is displayed.
The charging socket on the vehicle always indicates each operating condition (Charging, vehicle unlocked, fault etc.)
through two LEDs.
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=> Please use Attachments B1+B2 in this TIPS document to interpret the reason for the LED display (Note B1 is a
non-USA socket, USA does not have indicator lamps or a lock)
=> If a fault is found, rectify it in accordance with the details given in "Possible remedies/recommended actions" in the
attachment.
C) Fault without flash code or remedies under A+B would not serve any purpose
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•

Read out quick test, actual values and control unit event log data (from on-board charger + HV battery)
Please answer the following questions as accurately as possible
Then create a TIPS case with the above mentioned information

1. Exact description of the complaint? ___________
2. When did the problem first occur? Time: _ _ _ _ _
3. Is the problem reproducible? YES/ NO
3.1 Under which conditions does the problem occur?
Outside temperature _______
Service life
Weather
Other

°C/°F

_______
_______

Hours / days
Wet/dry

_______

4. If the vehicle is charging, has the charging period changed in any way compared with an earlier period?
Exact description of change compared with earlier period:
Before fault occurred: ______ Charging time in hours for SOC (=State of Charge = Charge level) from ____% to ____
%
Current:
%

______ Charging time in hours for SOC (=State of Charge = Charge level) from ____% to ____

5. At which SOC was charging started when the fault occurred? _______%
6. Does the charging process always terminate after a specific period of time? No / yes, after a charging time of :_____
min/h
7. Does the charging process always terminate at a specific SOC? No / yes, when the following SOC is reached: ____
%
8. Describe the charging infrastructure used and the specific charge levels
Charging

Not charging

Internet-

Manufacturer

Connection
Present?
Wallbox:

___

Domestic plug socket (with FI):

___

Domestic plug socket (without FI):
Public charging (with Plug&Charge):
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___
___

___
___

___
___

___
___
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___
Mains fuse with 12/16/32 A

___
___

Mains fuse with 12/16/32 A
___

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Public charging (without Plug&Charge):

___

___

___

___

Mode of payment for public charging: RFID / Phone / SMS / Credit card / Other: _____________

9. Which charging cable or which load mode is used?
Manufacturer:___________________

Charging cable designation/part number:__________________

Mode 2 (in USA: "Level 1")

______

Mode 3 (3.3 kW: in USA "Level 2")

______

Mode 3 (22 kW)

______

10. What happens when charging is performed with another charging cable?
Same fault profile___________ (Yes/no)
Different fault profile, accurate description:________________________________________________________
11. Do other vehicles in the charging infrastructure exhibit identical charging problem,s? Yes / no
Description:__________________________________________________________________________________________
12a. What does the indicator lamp at top left on the vehicle charging socket do in a fault case?
(It describes the status "charging cable inserted"; see also Attachments B1/B2) (Note B1 is a non-USA socket, USAdoes not have indicator lamps or a lock)
White______

Stays off _______

Comment:__________________________________________________
12b. What does the indicator lamp at top right on the vehicle charging socket do in a fault case?
(it describes the "Charging status"; see also Attachments B1/B2) (Note B1 is a non-USA socket, USA does not have
indicator lamps or a lock)
Green flashing____

Green____

Orange____

Orange flashing____

Red (fast flashing)______

Comment:________________________________________________
13. Which flash code is shown on the charging cable box (ICCU) (see also Attachments A1+A2)
14. In which loader program does the problem occur?
"Charging now"____

Departure time "w/o AC on" ____

Departure time with "AC on"____

15a. Which charging current is configured for the vehicle?
Charging current for vehicle:

8A___

12A___

13A____

Max____

15b. Which charging current is configured on the charging cable? (2 LEDs oder 4 LEDs)
16. Do you have valid access to the Vehicle Homepage? Yes / no
Comment:__________________________________________________________________
17. Do you have access to the vehicle through the Vehicle Homepage when it is not connected to charging equipment? Yes / no
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Comment:__________________________________________________________________
18. Do you have access to the vehicle through the Vehicle Homepage when it is connected to charging equipment?
Yes / no
Comment:__________________________________________________________________

19. Visual inspection/ assessment of charging cable?
Assessment:__________________________________________________________________________________
_____________________________________________________________________________________________
20. More complaints / information?

Description:____________________________________________________________________________________________________________

______________________________________________________________________________________________________________

Attachments
File

Designation

ENGLISH_A1_Description of the indicator lights and func- ENGLISH_A1_Description of the indicator lights and functionality of the ICCU.pdf
tionality of the ICCU
ENGLISH_A2_Table to interpret the flash-signals of the
ICCU.pdf

ENGLISH_A2_Table for interpretation of ICCU flash-signals

ENGLISH_B1_Description of the charging socket LEDs.
pdf

ENGLISH_B1_Description of charging socket LEDs

ENGLISH_B2_Flowchart to interpret the flash-signals of
the charging socket.pdf

ENGLISH_B2_Flow chart for interpretation of charging
socket flash-signals

Symptoms
Overall vehicle / Power supply / Battery/On-board electrical system / Battery function / Battery cannot be charged
Power generation / Engine management / Electric drive / Nonfunctional

Validity
Vehicle

Engine

Transmission

451.390

*

*

451.490

*

*

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