2000 watt Hybrid inverter as generator

[CurtisB]

A thanks to @TimeOutside for posting their 2000 Watt Removable Inverter Installation. This is basically their design with some more pictures. I plan to use this as an emergency generator if/when we lose power for a while.

The parts I used are: Inverted, Fuse Holder, Wire, 5/16 Lugs, Disconnect, Kydex sheet and a Crimper.

The threads on the battery terminals, inverter, and fuse holder are all M8-1.25. Needed one metric nut for the battery terminal with a 5/16 lock washer and washers.

All you folks who work with 2/0, respect man. My usual is 12 gauge and I wasn't ready for the ... challenge ... of working with 2/0. Every part of the job was a learning experience and, surprisingly, took longer than expected. The disconnect and fuse holders were both significantly larger than I had envisioned when shopping online.

So you got all this done and it's hook up to the stock Ford battery? No sleepy-poo issues? Man, all I know is if I did this when I had my stock battery, I'd be stranded somewhere in the desert.........in the dark...........hearing Coyotes calling my name...................

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[colinl]

To be fair, the HV is called on by the BMS on the 12v battery to charge it when it gets low. So in this setup, while not directly connected to the HV, the HV is involved by association/tangentially. But I agree that there is little warranty risk here since the "man in the middle" is the 12v battery. Not suuuuuuuuuuuper cheap to replace if somehow fried, but also not the thousands that would cost to replace the HV.

as a long time carfi guy who has had many systems over 1,000wrms but exactly zero systems that use a 12V 250A fuse like this, my greatest concern is definitely a short, overheating wiring, or a loose connection. a fuse like this and the wiring associated is far safer on the engine side of the firewall than in the passenger compartment.

but... I do get it. that adds a lot of wiring, which adds resistance, cabling gauge and cost. and with the quick disconnect and presumed lack of daily / frequent usage, it's relatively safe.

what's up with that ground, though? it looks like - and I hope I'm wrong - that it's grounded to the chassis and also connected to the battery monitor and negative terminal. surely not.?

 

[paneubert]

Thanks, I would have thought that when the motor is running, the 12V battery is charged from the ICE and not the HV battery.

Well, there is some black magic in there somewhere. We are making some assumptions based on what @TimeOutside observed when putting a sustained load on theirs. Whether it was the HV charging the 12v and by association powering the inverter versus the ICE powering the inverter, the 12v did not seem to go flat and maintained a reasonable charge.

They said in their thread...

• I tested a 1750 watt load for about an hour and and a no load for about a half hour, so I expect this inverter setup will work until the vehicle runs out of gas
• With an approximate 1750 watt continuous load
  • The internal combustion engine (ICE) will cycle through approximately 3 minutes running and 3 minutes off
  • Running this cycle for over an hour, the inverter got only slightly warm and the cables remained cool
• With no load except for the inverter idle power consumption
  • The ICE will cycle through approximately 3 minutes running and 20 minutes off
• I tried some lesser loads, like 2 incandescent bulbs and a blow dryer on low
  • The cycle was about 3 minutes with the ICE running and 12 minutes off

 

[TimeOutside]

First of all, thank you @not null for the mention. Like you, our plan is to use the 2kw inverter for any extended power outage at our home. Although I'll also use it off site on occasion.

... like, for your home?...

Yes. But I'm not following your concern that it won't do much. Obviously, it won't run an HVAC system. We won't be connecting it into our home wiring. But it will run both our full-size refrigerator and our mini-freezer. Both max out at less than 500 watts. Neither needs to run continuously. With some judicious door opening, letting them run once or twice a day is all that is needed. Our microwave runs at just less than 1600 watts. A 10,000 BTU window air conditioner has a starting and running watt of 3000 and 1200, respectively, not that we plan on getting one. But it's more than adequate at running some fans. For heat, we have a propane solution. Our TV, DVR, and sound bar take less than 200 watts, but it's unlikely we would use the inverter for them. The fuel consumption to run the fridge, freezer, and power up portable devices is negligible. Unless there is something I'm totally missing, the 2kw inverter solution seems pretty handy to me.

 

[not null]

as a long time carfi guy who has had many systems over 1,000wrms but exactly zero systems that use a 12V 250A fuse like this, my greatest concern is definitely a short, overheating wiring, or a loose connection. a fuse like this and the wiring associated is far safer on the engine side of the firewall than in the passenger compartment.

but... I do get it. that adds a lot of wiring, which adds resistance, cabling gauge and cost. and with the quick disconnect and presumed lack of daily / frequent usage, it's relatively safe.

what's up with that ground, though? it looks like - and I hope I'm wrong - that it's grounded to the chassis and also connected to the battery monitor and negative terminal. surely not.?

I'm not quite following your ground wiring observation. Wire 1 is the factory wire that grounds the truck. Wire 2 is the one I added. Bolt 3 connects the two and still grounds the truck.

 

[TimeOutside]

Note: I don't know when I'll ever get to it, but I do have Forscan Lite on my phone, so at some point I can watch the HV state of charge while also watching the 12V battery voltage. That said, I expect to find as the 12V battery drains that the HV battery keeps it charged, then the ICE kicks in to keep the HV battery charged.

 

[TheWizziard]

I'm all for folks modifying their Mavericks but this is one that I think would void your HV battery warranty in Ford's eyes and that juice just isn't worth the squeeze.

My Bluetti solar generator (1.1kwh) cost $440, and my 200w solar panel keeps it juiced up and not impacting my Maverick.

Almost every thread has to have a "void the warranty" post.

 

[The Real Maverick]

Note: I don't know when I'll ever get to it, but I do have Forscan Lite on my phone, so at some point I can watch the HV state of charge while also watching the 12V battery voltage. That said, I expect to find as the 12V battery drains that the HV battery keeps it charged, then the ICE kicks in to keep the HV battery charged.

No. Not really.

The ICE recharges the HV battery.
The DC/DC converter is constantly putting out ~14.5 V stepped down from the HV battery.

Except for leveling spikes, the 12 v battery is not doing a darn thing. With a constant load, you could remove the 12v battery from the truck (but it's good to have to said load leveling).

Try a simple test for yourself.
You don't need forescan.

With a volt-meter, test the voltage supply to your inverter. If it's above 12.6 power is not coming from the battery.

 

[TheWizziard]

Thanks, I would have thought that when the motor is running, the 12V battery is charged from the ICE and not the HV battery.

In the hybrid, the 12v battery is always charged by the HVB through a DC to DC converter. The ICE doesn't have a 12v alternator.
The HVB is charged by the motor/generator running off the ICE and/or through regen braking from the other motor/generator.

 

[710-oil-614]

Almost every thread has to have a "void the warranty" post.

Have you ever tried to make a warranty claim with Ford? If you sneeze the wrong way in your vehicle they will deny a warranty claim.

With all of the bitching and moaning that goes on in these forums about Hybrid batteries, deep sleep mode, BMS issues, SoC not being high - there's way too much smoke for me to make that modification when my Hybrid arrives considering the potential issues around the rather fragile BMS system.

To each their own.

 

[TheWizziard]

Have you ever tried to make a warranty claim with Ford? If you sneeze the wrong way in your vehicle they will deny a warranty claim.

With all of the bitching and moaning that goes on in these forums about Hybrid batteries, deep sleep mode, BMS issues, SoC not being high - there's way too much smoke for me to make that modification when my Hybrid arrives considering the potential issues around the rather fragile BMS system.

To each their own.

You have every right not to do modifications to your new Mav.

 

[710-oil-614]

Can you tell me more about your setup? 1.1kw = 1100w right? Is there a battery as part of it?

Correct. Bluetti and EcoFlow are two of the better known companies that make LiFePO4 "Portable Power Station" or also known as a solar generator (because they can charge via solar, but also through cigarette lighter (DC), or traditional outlet (AC).

I got mine on sale for $440 but it is currently $599. It is 1152wh in capacity and has a 1800w continuous output with 2700w peak.

https://www.amazon.com/BLUETTI-Port...mzn1.fos.1740e8b9-be2d-46a4-a376-9d8efb903409

I have an overlanding refrigerator that if the power goes only pulls 45w max so I will run that and my chest freezer and it will still run the HVAC blower motor in the winter for my furnace with ease.

I have a 200w solar panel that on a partly sunny day will still generate 100w and goes as high as 155w in full sun.

Should I need that I have 2 - 1800w dual fuel inverter generators that I run on 30lb propane tanks and can run them in parallel.

 

[710-oil-614]

You have every right not to do modifications to your new Mav.

Thanks, I know I do.

 

[BAScott62]

Whooop Whooop, I'm the warranty police!!

 

[MakinDoForNow]

I'm not quite following your ground wiring observation. Wire 1 is the factory wire that grounds the truck. Wire 2 is the one I added. Bolt 3 connects the two and still grounds the truck.

Looks like best possible ground to me.

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