DC to DC converter maximum limit/fuse size/type?

[MostlySafeBear]

For the Maverick hybrid, what is the rated (constant, not surge) amperage capacity of the DC to DC converter?

What is its fuse size, or is it a fusible link instead?

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[BrianA]

I have been looking too, and cannot find anything official. Someone on another thread said 250 amps at 14 volts. But, remember the power steering, ac, and a lot of other things that are not usually electric on a typical car are sharing in that power. (Pretty sure these run on 12 V, so as not to avoid high voltage wiring running all over the place.) Who knows how much is left over. I saw another post that said the kids putting huge stereos in their Ford Escape (which may be the same system?) were having 12 volt battery problems if they consistently pulled over about 1000 W from the 12 volt system which makes sense if they were also cruising and simultaneously using AC, power steering, etc. If anyone finds out for sure, please let us know.

 

[Mach 1]

Wow, you are going to get in on It. The highest draw for the 12v system is the battery recharge from HVB. I will go check the manual, see what it says.

 

[TheWizziard]

This question has been asked before by those of us wanting to install an 110v inverter. Maybe now that there are more vehicles out there we can get some answers.

 

[clavicus]

Wow, you are going to get in on It. The highest draw for the 12v system is the battery recharge from HVB. I will go check the manual, see what it says.

Wouldn't the HVB be pushing more power to the AC system on full load, for example, than the draw of the 12v battery that is basically trickle-recharging while you're driving?

 

[Darnon]

The Air Conditioning is direct high voltage DC, not off the 12V system. That's what the orange cable looping around the passenger side fender is going to.

 

[Mach 1]

Clav, you got it, that is what I was trying to say, I was just saying on the 12v side there is not hardly a draw. Just battery recharging/trickle charging.

There's alot more load going thru the 300v. Charging the HVB, AC, then discharging it, regen, alot more load jumping around in the 300v system.

I would guess, with this question, going to be how much can I hang on/load the 12v system, before it gets detrimental to charging/12v system. Invertor or stereo system?

 

[Bmr4mav]

This long and we still don’t know.

 

[BrianA]

Clav, you got it, that is what I was trying to say, I was just saying on the 12v side there is not hardly a draw. Just battery recharging/trickle charging.

There's alot more load going thru the 300v. Charging the HVB, AC, then discharging it, regen, alot more load jumping around in the 300v system.

I would guess, with this question, going to be how much can I hang on/load the 12v system, before it gets detrimental to charging/12v system. Invertor or stereo system?

Yes, I am wondering how big an inverter I can run for an extended period of time without overheating or otherwise shortening the life of the DC/DC converter. Also, have a small solar system with about 10 kWh of 12 volt battery backup, and while I don't really intend to do it, I am interested to know if I could use the 12 v off the vehicle to recharge if I have a row of cloudy days (and the generator is for some reason inoperable). Of course I can do that through an inverter also, but if I am just charging 12 volt batteries, it does not make sense to take the efficiency hit to step up through an inverter just to step back down in the battery charger and I don't want to mess with tapping into the 300V traction battery.

 

[bk101]

Did anyone ever get an actual number for this?

 

[Darnon]

Did anyone ever get an actual number for this?

265A with a 300A fuse according to the service manual.

 

[bk101]

265A with a 300A fuse according to the service manual.

Do you know how much is available to use out of that? wondering what the maximum safe amps/wattage i can use for a sound system

 

[paneubert]

Did anyone ever get an actual number for this?

Sort of.


Inverter Install: https://www.mavericktruckclub.com/forum/threads/2000-watt-removable-inverter-installation.44646/

Another Inverter Article:

https://www.mavericktruckclub.com/forum/threads/2000w-inverter.29841/



Another inverter: https://www.mavericktruckclub.com/forum/threads/2000-watt-hybrid-inverter-as-generator.54063/

 

[BlueSpec1]

Workshop Manual:
414-05 Voltage Converter/Inverter Description and Operation
2023 - 2024 Maverick

Direct Current/Direct Current (DC/DC) Converter Control Module - System Operation and Component Description

Normal Operation and Fault Conditions
The DCDC is liquid cooled by the (electric) motor electronics cooling system that consists of a radiator, coolant hoses, and a coolant pump.
The DCDC monitors its temperature internally. The DCDC requests a coolant flow speed and monitors the coolant pump status from the BECM via HS-CAN .
If the internal temperature increases higher than 81°C (178°F), P0A94:4B sets and the output current is limited until the over-temperature condition clears.
If the internal temperature becomes excessive, DTC P0D32:00 sets and the DCDC goes to standby mode (DCDC disabled) until the over-temperature condition clears.
Presence of this DTC results in CHECK CHARGING SYSTEM being displayed in the message center and the 12-volt battery discharged.
Reduced or no functionality of 12 volt systems (such as the headlamps, and HVAC blower motor) may also be noticed.

• DTC Fault Trigger Conditions
Possible Sources
• Low coolant level
• Airlock in system
• Coolant flow restriction
• Electric motor electronics coolant pump
• Electric motor electronics radiator
• Restricted airflow through motor electronics radiator
• BECM
• High ambient temperatures

...

DCDC Operation.
The DCDC is responsible for maintaining and charging the 12 volt battery. The ISC/ SOBDMC sends a HEV wakeup signal to the DCDC through a hardwired circuit.

The DCDC is liquid cooled by the electric motor cooling system circuit. The electric motor cooling circuit uses an electric motor diverter valve that acts as a system thermostat, allowing the coolant to flow within the motor circuit while the motor warms. As the coolant warms, the diverter valve slowly opens to allow coolant flow to the radiator.

The DCDC communicates on the HS-CAN1 with or without the high voltage contactors closed. A wake up circuit from the ISC/ SOBDMC activates the module processor.
If the wake up circuit fails and high-voltage is present, the DCDC still charges but with a delay.

Faults with the DCDC that cause low or excessively high 12 volt battery voltage result in the DCDC sending a network message requesting the CHECK CHARGING SYSTEM message be displayed in the message center.

The DCDC is protected by a 50 amp high voltage low current fuse located in the high-voltage BJB .
The DCDC steps the high-voltage down to a low-voltage (between 13.0 and 15.5 volts, depending on vehicle needs), providing power to the vehicle low-voltage battery systems.
Depending on the vehicle and environmental conditions, the DCDC is capable of outputting up to 265 amps to the 12 volt battery.

 

[Darnon]

Do you know how much is available to use out of that? wondering what the maximum safe amps/wattage i can use for a sound system

The modifier guide indirectly suggests 155-170 amps usable.

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