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Discussion Starter · #1 ·
As SunRun does not service my state, and the need to integrate the Home Integration System with an existing solar install (replacing a 4 year old 10kw Fronius inverter) I need to stagger the install, with the Charge Station Pro being installed first. I reviewed everything I could find (YT vids, spec sheets, etc...) and am left with a few questions, hopefully someone has found the answers to:

1. Do we know what rating of the DC power coming from the truck to the Delta BDI?

2. What are the NEC wire requirements for that DC power?

3. When that wire is combined with the 100a AC wire, what is the required minimum conduit size from the BDI to the EVSE?

4. Can the BDI loads output be run to a subpanel equipped with a manual interlock?

This system is going to be slick with new solar installs. Not so much with older ones, not done by SunRun...
 

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I wish I could help you out @PV2EV but I haven't dealt with a project like this. I'll bump the thread up because I'm interested to see what can be done to get your charge station pro connected to your home system.
 

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As SunRun does not service my state, and the need to integrate the Home Integration System with an existing solar install (replacing a 4 year old 10kw Fronius inverter) I need to stagger the install, with the Charge Station Pro being installed first. I reviewed everything I could find (YT vids, spec sheets, etc...) and am left with a few questions, hopefully someone has found the answers to:

1. Do we know what rating of the DC power coming from the truck to the Delta BDI?

2. What are the NEC wire requirements for that DC power?

3. When that wire is combined with the 100a AC wire, what is the required minimum conduit size from the BDI to the EVSE?

4. Can the BDI loads output be run to a subpanel equipped with a manual interlock?

This system is going to be slick with new solar installs. Not so much with older ones, not done by SunRun...
You don't need 100amp to do the backup function, not sure if you care about that at all.
 

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Discussion Starter · #4 ·
Thanks. For #4, I don't think I can connect the BDI AC load output to an interlock in my garage subpanel because the Solar output is run to my 400amp meter box from a my barn subpanel. I think I need to move the solar output to the garage panel to simplify the system, when the BDI is installed.
 

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Discussion Starter · #5 ·
You don't need 100amp to do the backup function, not sure if you care about that at all.
I think I should clarify; The BDI has the following main connections;

1. DC solar input

2. AC EVSE Charger (for me that will be 100amp)

3. DC High Voltage Battery Input (in our case the F-150)

4. AC output, that runs through a grid disconnect and critical loads tap

I was asking about combining 2 & 3 in the same conduit. But I have bigger issue in that 1 & 4 are 90' apart in my inteded install.

Does anyone know if solar panel DC strings can be run 90', and if so, what would the conduit size be for 10kw?
 

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2. AC EVSE Charger (for me that will be 100amp)

3. DC High Voltage Battery Input (in our case the F-150)

I was asking about combining 2 & 3 in the same conduit. But I have bigger issue in that 1 & 4 are 90' apart in my inteded install.
The impression I get is that the Ford Charger Pro, uses the same conductors running from the the HIS system. At both ends the 240v ac connections are switched out to divert the 400cDC out of the truck back to the house via the house side switch which then sends it to the inverter.

When utility grid is restored, the switches reverse and the trucks battery resumes charging.

How many conductors in the conduit? 3 is what I suspect.
AC charger mode 120ACx 120ACy & ground
DC backup mode 400v+ & 400v- & ground
 

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I think I should clarify; The BDI has the following main connections;

1. DC solar input

2. AC EVSE Charger (for me that will be 100amp)

3. DC High Voltage Battery Input (in our case the F-150)

4. AC output, that runs through a grid disconnect and critical loads tap

I was asking about combining 2 & 3 in the same conduit. But I have bigger issue in that 1 & 4 are 90' apart in my inteded install.

Does anyone know if solar panel DC strings can be run 90', and if so, what would the conduit size be for 10kw?
I’m not sure about the distance exactly but from my studying of solar panel installs (basically YouTube and other internet articles) DC current from solar panels loses efficiency when traveling long distances, but if that DC current is converted to AC current at the panels (micro-inverters) there is much less loss of energy when traveling significant distances. I’m looking at a DIY solar install for my home and likely need to go at least 100 feet or more from the panels to my house panels and if I do this I will need to convert the DC current the panels put out to AC current as close to the panels as possible from what I’ve read. Hope this helps.
 

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Discussion Starter · #9 ·
The impression I get is that the Ford Charger Pro, uses the same conductors running from the the HIS system. At both ends the 240v ac connections are switched out to divert the 400cDC out of the truck back to the house via the house side switch which then sends it to the inverter.

When utility grid is restored, the switches reverse and the trucks battery resumes charging.

How many conductors in the conduit? 3 is what I suspect.
AC charger mode 120ACx 120ACy & ground
DC backup mode 400v+ & 400v- & ground
The schematic in the Ford branded Delta Bi-Directional Inverter (BDI) spec sheet show separate runs/input/outputs for AC and DC. I hope you are correct, and the BDI chould be able to do that, as the grid down cases are;
1. Power to house from Truck
2. Power to house from Solar
3. Power to house from Solar & Truck
4. Power to house & truck from Solar

No case uses both AC and DC.

My path is to prep the install for the charger with a 1.25" conduit for three conductors and if there needs to be a separate run for DC, install another conduit later, which is what I wanted to avoid. Otherwise I can wait. Given I ordered on 4/12, by the time I have a build date, others may have already have the HIS installed by SunRun.
 
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Discussion Starter · #10 ·
I’m not sure about the distance exactly but from my studying of solar panel installs (basically YouTube and other internet articles) DC current from solar panels loses efficiency when traveling long distances, but if that DC current is converted to AC current at the panels (micro-inverters) there is much less loss of energy when traveling significant distances. I’m looking at a DIY solar install for my home and likely need to go at least 100 feet or more from the panels to my house panels and if I do this I will need to convert the DC current the panels put out to AC current as close to the panels as possible from what I’ve read. Hope this helps.
I am afraid you may be correct, which would require the BDI be installed in my barn (where my panels are), and maybe reroute the AC output (solar and critical load) to the garage. This means I would have to either a. charge my truck at the barn, or b. install a second charger in the garage (and move the truck to the barn in a grid down situation). B is the most likely outcome. It also complicates a manual disconnect which I think need to be outside per code.

I don't believe the BDI works with Micro Inverters, so beware.
 
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The schematic in the Ford branded Delta Bi-Directional Inverter (BDI) spec sheet show separate runs/input/outputs for AC and DC. I hope you are correct, and the BDI should be able to do that, as the grid down cases are;
I would love to get a copy of this document, is there a link to it, or can you attach the PDF to the post/thread?
 

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Does anyone know what size inverter comes with the Home Integration System? The listing on AEE Express says the model is the E10_BDI inverter which I think is like 10 KW. However, my invoice on the order for the Home integration system from AEE Express indicates it is coming with the E4_BDI which is much smaller, maybe like a 4KW? Please help as this is crucial for planning my DIY solar install in a state that SunRun does not service….
 

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Discussion Starter · #16 ·
Wow 4kW for $3k, steep. I too had assumed it was 10kW which is what need to replace my Fronius. Please us know what you find out.
 

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Wow 4kW for $3k, steep. I too had assumed it was 10kW which is what need to replace my Fronius. Please us know what you find out.
I’m trying hard to get details but it’s almost impossible. Ford knows absolutely nothing about the components of the system. AEE Express keeps transferring me to Sun run and doesn’t seem to have any way of giving me answers. And Sun Run won’t even talk to me because I’m not in a state that they service. So maybe if someone from a SunRun service state called they would give them more info….it’s just about ridiculous honestly.
 
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