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swtaylor89

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This has been my project for the last two weeks, in between chemotherapy and deer season. Installed a 125 amp subpanel in the garge. Powering my Ford Charge Station Pro (FCSP), a 14-50R receptacle, a 20 amp receptacle, and power outside to my patio. Also integrated a generator inlet in the garage, so I can power up my house with Pro Power Onboard without having to go outside park the truck on the lawn at my existing generator inlet. BLUF: It all works and I am confident it will not burn down my house!

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FCSP operating at maximum power (80 amp). I torqued all terminals and lugs to spec. Then after it was running at full 80amp load for an hourse, I checked every terminal, lug, and breaker with my FLIR thermal camera. Breaker lugs are rated max 75C. All other terminals and wires are rated max 90C. All were 30-40C! I plan to check them all again in a month to make sure nothing has gotten loose. But I don't forsee finding anything wrong in a month or years.

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Generator inlet powering my house as I type this post. Since I already have a generator inlet on the side of that house, I needed to use a manual transfer switch (MTS) to select which inlet I want to use. If I just put them two inlets in parallel, the male prongs of the unused outlet would be energized for some idiot to stick their fingers in. It would also allow some idiot to accidentally hook up two sources at the same time, which would probably be exiting to watch from a distance. So I put in that double-throw switch to select which inlet gets sent to the interlock breaker on the main panel. In the spirt of simplification by elimination, I hard wired the generator cable rather than putting in another inlet. For the code nazis, close your eyes for 30 seconds. The ground is disconnected where the generator cable enters the subpanel. This prevents the truck's GFCI protection from tripping due to the house's ground-neutral bond. The truck and the cable are protected by the truck's ground and GFCI. The subpanel onward are protected by the house's ground-neutral bond as it always is. It is perfectly safe, there is absolutely no loss of protection of any kind anywhere. If you're going to make 2 page long rambling comment about how this is wrong, save your keystrokes please.

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This also required rewiring my flagpole lights and an existing outlet on the side of the house. That old hot mess is now done up all nice with a photocell, switch, and the new 20 amp duplex in an in-use cover. Those are all on a new 20 amp GFCI breaker no the main panel. The conduit trough made wiring all those connections very simple.

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Pictures from the work in progress.

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Awesome project, and write up!! Big fan of adding outlets anywhere you can when doing electrical projects too, because hey, why not if you're in there doing it anyways? Did a similar setup for mine as well minus the double gen inlets. Added 240 as well for mobile charger incase FCSP fails. Great work and best with the chemo treatments!

Ford F-150 Lightning Installed FCSP, Generator Inlet, MTS, Subpanel, Conduit, and my entire body hurts. 20230915_221000


Ford F-150 Lightning Installed FCSP, Generator Inlet, MTS, Subpanel, Conduit, and my entire body hurts. 20240520_184055
 
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I'd imagine there's another shutoff inside, but from the pic it appears your natural gas shutoff is open.
 
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Runaway Tractor

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I'd imagine there's another shutoff inside, but from the pic it appears your natural gas shutoff is open.
Well look at that. Never noticed. That's a quick connect for my dual-fuel portable generator. There's another one on the patio for a grill. No need for BBQ tanks or gas cans!
 

Howard_Scott_Warshaw

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Obligatory "should have put it in EMT".

Clean install. Now get some PV interconnected and you'll be able to shove solar generated electrons into the truck.
 
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Obligatory "should have put it in EMT".
Should have used 2" instead of 1.5" conduit. Shoving all that 1/0 cable through all those LBs was really rough. I didn't have the strength to do it thanks to the 6 months of chemo sucking the life out of me. My neighbor helped pull while I pushed and we got it through.

Clean install. Now get some PV interconnected and you'll be able to shove solar generated electrons into the truck.
My original plan included and EG4 6000XP inverter and at least 5kwh of batteries as UPS for a critical load subpanel. That got value engineered out due to cost.

If I ever do it, I'll put an EG4 18K and outdoor 13kwh battery on that wall outside. and a small ground mount solar system. The roof is not ideal since it faces 280 degrees west.
 

bmwhitetx

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Did a similar setup for mine as well minus the double gen inlets. Added 240 as well for mobile charger incase FCSP fails. Great work and best with the chemo treatments!
What is this for? Is it builder-installed or some retrofit?
Ford F-150 Lightning Installed FCSP, Generator Inlet, MTS, Subpanel, Conduit, and my entire body hurts. 1733340788081-w0
 

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77C and 64C in lower left 2 photos
I was only going by the text, didn't see numbers in the picts. That still wouldn’t concern me too much. Probably why the instructions required 90C wire.
 

kstype

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Thank you. It's been a very trying 4yrs. Last chemo treatment (for now anyway) is actually tomorrow.
Yes - wish you much success with your treatments and hope they don’t drag you down too much! Keeping you in prayers! Thanks for sharing such great detail on your project - My electrician who installed my charger (and my normal generator years ago ) is also adding a generator port to the garage next to my charger and a switch to let me toggle between the original generator port and the new one for the truck.
 

StaggerLee

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I noticed the gen plug in your 1st picture is different than what's connected to your truck in a later picture - did you swap out the cable?

I really appreciate this thread. I've been considering doing it myself for a long time, and this might just be enough to get me over the hump. The FLIR camera images are also pretty cool (no pun intended).
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