Ford Lightning Pro Power Onboard failure on the last weld of the project

[hturnerfamily]

I also don't think the LIGHTNING employs any type of 'breakers', but more like FUSES, which is why you have the 'reset' buttons in the bed... so, heat does not seem to be the culprit.

I can imagine, though, that welders create different sources of nuisances to an INVERTER versus the typical tools, extension cords, and home circuits being powered by the ProPower output... while we can hope that Ford's engineers imagined every conceivable electrical tool and device to be used by the ProPower, it's also possible that the harmonics and other parts of the somewhat unique qualities of WELDING is also different than most... the process, and the electronics of the INVERTER and other equipment within the truck, may not play well together... somewhat like the condition we all talk about when it comes to the 'bonded Neutral' issue...

it should be simpler, but, well....

a gas or similar generator, though, is not designed the same... it's output is solely due to the power being generated by the running engine, and may can be much more 'forgiving' of electrical ups and downs while welding... but, a pure battery DC to 120v/240v AC output might be a different animal.

I think, too, you might search out a line conditioner, just to see...

Check if there are 'Inverter friendly' welders...

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[ElectrifyingMe25]

Not all power loads are created equal. You could have a highly inductive load that's very hard on the inverter. Also your welder could be creating a lot of high frequency harmonics that's backfeeding into the inverter. Harmonic pulses can cause the voltage on DC bus capacitors in the inverter to creep up in voltage and cause a fault. In industry, line reactors rated for the current can be put in series with the welder to block the noise (harmonics). But.... it may just be a faulty inverter. If I were using my truck on crazy loads, I would use a line reactor and an active power filter that's rated for the maximum load the truck can source.
Grainger, MSC, and Automation Direct sell Line reactors and active power conditioners rated for your truck's output power. They may help.

I'm curious to know what you find. Best of luck.