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Need help with Ford-Azure Transit Connect battery diagnosis

9531 Views 96 Replies 11 Participants Last post by  Ron_84
Hi i have a Transit Connect electric and one half of the batterypack wont connect/engage does anyone know soething about this cars anymore? i am suspecting the BMS but no fault code or anything is showing, ESS1 stays in "contactor state" as first picture shows for a while then it disconnects, ESS2 shows "xxxxC400" for just a second then it changes to xxxxC600 and contactor voltage shows up and the car is running on one half..

Thanks Robin
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Hi i have a Transit Connect electric and one half of the batterypack wont connect/engage does anyone know soething about this cars anymore? i am suspecting the BMS but no fault code or anything is showing, ESS1 stays in "contactor state" as first picture shows for a while then it disconnects, ESS2 shows "xxxxC400" for just a second then it changes to xxxxC600 and contactor voltage shows up and the car is running on one half..

Thanks Robin
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Hi Ron I have same Azure 2011 with like battery problem. I trying about one year to resolve the problem but any success, and about one week ago i locate the damaged board. I don’t know what does it means (2-6) maybe second pack and board number 6, but I know, that all boards is the same.
May i ask why did you need the master BMS, what is the problem?
My advice: first check all cell tensions, if it present. Directly it is possible with TCBEV monitor, then check differences between cells, not more than 0.5V, if more it’s critical.
For example, this screenshot is my problem
 

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Hi!

I have checked all 384 bolts :) also checked all 6 contactors, both precharge resistors and a some other parts too... all 192 cells are between 3.785 and 3.791, there are no internal fault codes in the two BMS so it always tries to connect but fails and stays disconnecteded after a while only connecting pack 2....

i have 2 Spare BMS one "A" and one "B" module, and one complete extra battery pack, also i got an empty battery pack with som bms slaves and other stuff...

When i try the other two BMS modules in the car no half wants to connect and it throws some other fault codes and that is making me suspect that the BMS modiles i have ar all broken exept one "B" module....


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Hi so, start from the very beginning: we have two independent battery packs in hv battery. Each pack contains one master and 8 slave BMS and 96 battery cells (let’s say driver side is pack A and passenger side is pack B). As I understood you have the problem with pack B, same as mine.
Ok, mine experience:
1. All cells is good and tensions is normal, without dig differences ( not more 0.2V, more than 0.5v - battery faulty)
2. I changed master BMS from pack A to pack B - problem still active (so, master BMS is the same and good)
3. I changed slave BMS to each other and problem is floating only around one concrete slave BMS.
So, we can say that all BMS is interchangeable.
TSBEV can measure the tension of each cell and report it in this windows (look the screens) and generate the trouble code.
But you have no any codes, how it may be possible? May be wrench or turtle on dashboard?

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I am from Georgia, Tbilisi
You post the screenshots, where we can see information from ESS:pack 1 and pack 2. I don't know exactly what does it means, but on left side of the screen must be information about each cell, tension. And if you can see pack1 and pack2 , i thinck, that master BMS is good, and may be you have older version of program
 

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Hi,
Very interesting log. Really, I am not expert, but I think, it is possible to say something.
Master BMSs, A and B, is working properly (they could read all information about battery).
Incomprehensible situation with temperature: ESS Coolant Temperature 5 °C., pack1 Hybrid Battery Temperature Sensor 0 – 6.889999 (DegC), pack2 Hybrid Battery Temperature Sensor 0 – 14.68999 (DegC).All packs is in one box and cooling with the same coolant. Why is it so different, maybe the cooling ring is clogged and BMS blocking pack? Need to check.
Leakage Resistance (Overall)- 192200 (Ohm), Leakage Resistance (Contactors Open)-1225800 (Ohm) for pack1 and Leakage Resistance (Overall)-338200 (Ohm), Leakage Resistance (Contactors Open)-598600 (Ohm) for pack2: small value, must be more than 1Mom and upper. Need to check HV cable and all connection. Will be good to try to change HV relays from pack1 and pack2 to each other, maybe contacts is damaged. Are there any signs of rust?
 

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Yes, In mine log Contactor Voltage Positive, Contactor Voltage Negative both packs are 0 because the ignition key is in 2 position and not in 3(III (Start) — connects the high voltage system and readies the vehicle for operation).This tension appears, when contactor is closed (I think). But, I don’t understand, how they calculate Contactor Voltage Total,355,75, if Contactor Voltage Negative,169,85+Contactor Voltage Positive,137,85=307.7V? I think, the Leakage Resistance (Overall),192200 on pack1 is too small, it must be grater min. 1Mom (1.6Mom in mine log)
So, this is a HV scheme, if you have not.
 

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Ok, the same…cold:). Is it European or Norse American version of BMS, or it’s the same versions?
Xa.. After two weeks standing, first pack of my battery damaged too, for itself:unsure:, same as second.I have not battery!!!!!!!:mad::mad::mad:
 

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Hello so, after about 2 weeks of inactivity, I cannot start the battery, a red triangle appears, the car does not move, despite the fact that I myself have returned home before. I loose connection with HV battery, but I can see slave BMS boards. In PACK 1 all boards is good (I think), but in PACK 2 appeared one more broken (so, now its two broken). And I have the P0A0A-00 High Voltage System Interlock Circuit, but I don’t know, what does it means, because it not the same (for example), as P1A86 VCU Secondary DC High Voltage Inter-lock Circuit Low.
If it helps, this is new log file.
 

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View attachment 126183 View attachment 126184
View attachment 126181 Happy days tonight!! i fanaly got my Azure dynamic running on both packs agan:D:D many many hours of testing and thinking and finaly it was ah software problem... flashed the BMS modules to 14,20,6 from 4,1,11 and it connected as it should both when charging and started the car.
My congratulation, Ron, nice job. I'm thinking too about flashing, because nothing helps my problem, second pack still not working. Can you share specification, how you flashed packs, which soft and dump you use?
Thanks.
 
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