ProPower Onboard 7.2 kW engine keeps running when using 220 outlet

[Draper C]

I recently used the 220v outlet for the first time. My wife got a plug-in hybrid Volvo and because of the location of the closest outdoor outlet, we were unable to charge it by connecting it to the house.
I ended up doing some research and found an adopter a lot of people use when powering their campers from the truck.
The first time it worked great, the engine cycling off and on as it should.
Since then, the engine runs consistently and this charger only pulls 3.7 kW.
Has anyone run into this issue? If so, is there a fix for this?

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[Nommpop]

If you're pulling enough current, the truck won't shut off. My truck turns on and off when powering my camper, but doesn't shut off when powering my house

 

[tsigwing]

Its a neat test, and yes, once the battery is drained, you have to both recharge the battery and supply the load to the outlet.

What is your long term solution?

 

[Porpoise Hork]

The ICE will sometimes stay on if the total load on the inverter is over 3.0-3.5 kW for a sustained period of time. It will also stay running if the 12v battery SOC is low. If you keep a spare key fob in the truck and the HVAC blower motor on 5 when in generator mode the 12v charging system will keep the output above 14v. Otherwise it will drop to 12.2-12.8v and slowly deplete the SOC on the 12v batteries. The system will then keep the ICE running continuously when in this state to prevent the 12v batteries SOC from dropping too low.

 

[Draper C]

Its a neat test, and yes, once the battery is drained, you have to both recharge the battery and supply the load to the outlet.

What is your long term solution?

We are getting a 240v ChargePoint Charger installed this week for the Volvo.
I’m just shocked the engine is constantly running when I’m basically pulling half the generators total output.

 

[Draper C]

The ICE will sometimes stay on if the total load on the inverter is over 3.0-3.5 kW for a sustained period of time. It will also stay running if the 12v battery SOC is low. If you keep a spare key fob in the truck and the HVAC blower motor on 5 when in generator mode the 12v charging system will keep the output above 14v. Otherwise it will drop to 12.2-12.8v and slowly deplete the SOC on the 12v batteries. The system will then keep the ICE running continuously when in this state to prevent the 12v batteries SOC from dropping too low.
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I have even gone the extent of running the truck for 10 minutes before I plug into the generator. Everytime the engine kicks in within 10 seconds and never cycles off.

 

[Draper C]

The ICE will sometimes stay on if the total load on the inverter is over 3.0-3.5 kW for a sustained period of time. It will also stay running if the 12v battery SOC is low. If you keep a spare key fob in the truck and the HVAC blower motor on 5 when in generator mode the 12v charging system will keep the output above 14v. Otherwise it will drop to 12.2-12.8v and slowly deplete the SOC on the 12v batteries. The system will then keep the ICE running continuously when in this state to prevent the 12v batteries SOC from dropping too low.

I have even gone the extent of running the truck for 10 minutes before I plug into the generator. Everytime the engine kicks in within 10 seconds and never cycles off.

 

[Porpoise Hork]

Have you checked it with Forscan for any system faults? If there's any it can prevent it from cycling the ICE properly. Also when enabling generator mode are there any warning messages?

If you don't have one you might also want to get a bluetooth OBD dongle and depending on if you have iOS or Android appropriate app that you can use to monitor the 12v and hybrid battery charge levels when in generator mode to see what's going on. The ICE should remain off when the HV battery charge is between 40-63% provided the load is below 3.5-3.7KW, and temps are not too high.

 

[Draper C]

I spo

Have you checked it with Forscan for any system faults? If there's any it can prevent it from cycling the ICE properly. Also when enabling generator mode are there any warning messages?

If you don't have one you might also want to get a bluetooth OBD dongle and depending on if you have iOS or Android appropriate app that you can use to monitor the 12v and hybrid battery charge levels when in generator mode to see what's going on. The ICE should remain off when the HV battery charge is between 40-63% provided the load is below 3.5-3.7KW, and temps are not too high.

I enable generator mode every time with zero warning lights.
I spoke with my service advisor today and he was able to check the 12v via their system and it was running at 65% while I was driving on the interstate.
I am swinging by the dealer tomorrow and they will be testing the hybrid battery pack.

 

[turbopilot]

We are getting a 240v ChargePoint Charger installed this week for the Volvo.
I’m just shocked the engine is constantly running when I’m basically pulling half the generators total output.

Ford limits how much of the 1.5 kWh lithium battery can be used for ProPower on Board or propulsion. Typically only 20% to 30% of the battery is actually available. So anytime continuous loads exceed around .5 kW the engine will run continuously.

 

[Snakebitten]

Ford limits how much of the 1.5 kWh lithium battery can be used for ProPower on Board or propulsion. Typically only 20% to 30% of the battery is actually available. So anytime continuous loads exceed around .5 kW the engine will run continuously.

^^^ this

You shouldn't be too surprised if you are taxing that little tiny 1.5 KWH high voltage battery at a rate that would require it to continuously charged anyway.

Or put another way, if the ICE was going to be required to run 1 minute on, one minute off, I bet it's healthier in the long run to just keep it running?

The 7.2KW inverter is a FANTASTIC inverter, in my opinion. I use it for days at a time. Performs like a champ. But that tiny little buffer, the high voltage battery, is definitely a limiting factor on ICE recharge demand cycles. Even a conservative increase in size would greatly improve the threshold for requiring the ICE to run continuously.

 

[Porpoise Hork]

Agreed. Ford really dropped the ball with the HV battery capacity on the PB. Should have doubled its size and could have easily accommodated the slightly larger case it would have required. I mean my mom's 2022 Toyota Highlander hybrid has a 1.9 kWh battery...

 

[Davexxxx]

I don't have hard numbers but I have used the PPOB numerous times powering my camper. Once for as long as 12 continuous hours.

Seems that if the demand is in excess of around 1750W, the ICE doesn't cycle. Just from casual observation, no documentation.

So, doing some heavy work, like recharging a depleted 600ah battery bank, ICE won't shut down but once charged and mainly just running the camper aircon and a few other light loads, ICE cycles as it should.

 

[Snakebitten]

On my 2022, it's about a 12 Amp load threshold for ICE not turning off. Not perfectly consistent at 12 Amps/~280V, but close.

So ~3300 watts?

Note this is combined load of the truck itself + ProPower draw. Depending on what HVAC settings are in the truck, as well as headlights etc, I can shift some of that headroom towards ProPower.


I'm currently at Oshkosh and am in a tiny RV that barely is drawing at all. The 18,000 btu air conditioner isn't even needed. ?
So I'm running off a solar generator(s) and would only need ProPower for charging it back up. Love the utility of this truck combined with the multitude of options we have for energy storage these days. Remarkable time we are living.

 

[turbopilot]

On my 2022, it's about a 12 Amp load threshold for ICE not turning off. Not perfectly consistent at 12 Amps/~280V, but close.

So ~3300 watts?

Note this is combined load of the truck itself + ProPower draw. Depending on what HVAC settings are in the truck, as well as headlights etc, I can shift some of that headroom towards ProPower.

Yes, that high voltage heat pump represents a considerable load on the battery.

The PowerBoost HEV was designed to achieve a marginal increase in fuel economy. PPoB just came along for the ride. A great idea for an add on. But the F-150 is a pickup that tows things. So much energy is lost that could be saved via regenerative breaking when towing. It is 2025. The PB was introduced in 2021 along with PPoB with no improvement to the the basic HEV. What is Ford thinking? A 10 kW or 20 kW battery would fundamentally change the efficiency of the PB and dramatically improve the functionality of PPoB.

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