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Discussion Starter #1 (Edited)
Well I finally bit the bullet and put down a deposit on the 10KW lithium ion pack. Gonna try to install ourselves and Ill do as others have here and document the process. While I am waiting for the pack to be ready, I have a few questions for the folks that have done the upgrade: 1) how hard was the install, and how hard is the Sevcon controller to remove? The charger looks simple but the controller seems in the middle under alot of metal structure. 2) Are there any charging tips or tips in general for cold weather? Will the pack charge under 32 degrees? Mine will be used in the mountains of WV, very deep terrain and it does get pretty cold in winter. 3) are there any maintenance tips and what range do you guys with lithium keep the pack in? Ive been reading that lithium ion batteries like to be around 50-60 %, was thinking 20-80% is a good range to try to keep them in unless you need that extra 20% for something - similar to what they recommend for Tesla or other EV cars. Any info you guys can share is great and Ill post more thru the process too.
 

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Subscribed. Being in WV does your EV cut out now going up steep terrain? I know you have the hills to fully test it. Lol

I’ve been curious if moving to Lithium would solve this issue. All of our carts cut out now going up very steep terrain. Look forward to watching this thread. Thanks.


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Controller is easier to get out than the charger for me. Just be sure and disconnect the MPC. Mark and take pictures of cable connections. Be careful to not touch any pos n neg cables, the connections on the controller are close together. wrap wrench for removing cables w black tape.
 

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All straight forward if the battery pack is removed. If not remove the ign key. Remove the 35 way ampseal by lifting the small catch on one side then pulling it off the Sevcon, You can slide a small screwdriver in the side of the catch to release it. DOnt use force, you dont have to. Now the vehicle cant go live and turn on the contactor. Remove the cable from the contactor to Sevcon (Positive) Leave the feed in place its safe and held out of the way. Take off the assorted cables connected to the negative post. I would put a small cable tie through so none are lost/ dropped. Remove the negative cable and again tie to one side away from the battery pack. If unsure wrap the crimped end with insulating tape. Cable tie to the plastic of the front of the seat is a good place to get it out of the way. The Motor cables are normally marked to match the sevcon connections. If not mark on masking or insulation tape, or use a thin paint marker pen on the cables. Even if its simply front , middle and back. or . .. ...
4 Bolts hold the sevcon to the vehicle frame, or take it out with the right angle frame attached in the center of the seat.
Of all of the steps the most important is the release of the catch on the 35 way Ampseal, it can get broken, I have a customer vehicle at the moment wher it has previously been snapped off. The connector simply falls out . Its now cable tied to the frame. Its a real pain to replace the connector / housing, but not impossible.
 

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Yours is a 2016, so it may be different than my 2013 dashboard, but I kept the hour meter and the flashing charge indicator.

Here is the link to my install for those that haven't read it: Ordered The Voltronix USA 160Ah Lithium Ion Kit
 

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Ask Voltronix for a copy of their installation booklet. They rightfully do not release it to anyone who asks, but if you have started the purchase process I think they might send you a copy. I think your confidence in your ability to self install the kit will be greatly increased by reviewing it.

2) Are there any charging tips or tips in general for cold weather? Will the pack charge under 32 degrees?

My 10 kWh Voltronix pack was installed in 2014 and is still functioning well. I do not keep it plugged in; I charge it and use it until the battery is at about 30% (according to the SOC ribbon indicator) then charge it again. The BMS will reduce or prevent charging depending on the temperature of the battery cells. I have found that if our Ranger EV Li is in an insulated garage the temperature seldom gets below 40 F even when it is below 20 F outside. Charging is impacted at about 50 F. You can use the vehicle in cold temperatures but charging might be an issue. The battery pack does "heat" up as it is used so one strategy is to use it before starting to charge. Again, if the temperature is not right the BMS will not turn on the Delta-Q charger, or will allow only low current, so no harm. If you can keep the Ranger EV Li in an insulated garage these issues are much reduced. Even an un-insulated shed is better than parking it in the open. Also, remember the temperature that matters is in the battery pack where the sensors are mounted; it is not a reference to the ambient air temperature. Please do post your progress as we will all learn something from your experience.
 

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Discussion Starter #7
Subscribed. Being in WV does your EV cut out now going up steep terrain? I know you have the hills to fully test it. Lol

I’ve been curious if moving to Lithium would solve this issue. All of our carts cut out now going up very steep terrain. Look forward to watching this thread. Thanks.


Sent from my iPhone using Tapatalk Pro
We do have some really steep terrain there, I drive mostly on the gravel roads and it will slow down at some of the steeper hills, Id guess some are close to 20-25% grade, but the EV never stops. If it is in low it will climb same speed no issues but for the roads we dont use that mode only off road. one time we had four people (2 in the back) and it slowed down almost to a crawl so I hit low and it almost dumped them out LOL. When you say cut out you mean it just stops? what if you flipped to low when it did that I wonder. My cabin is at 1200' and the rest of the development where we drive it higher for the most part (up to 3000') so we can go to 40% and then only use less than half coming back, cause it will regenerate 5-10% coming down those steep hills.
 

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Discussion Starter #8
Ask Voltronix for a copy of their installation booklet. They rightfully do not release it to anyone who asks, but if you have started the purchase process I think they might send you a copy. I think your confidence in your ability to self install the kit will be greatly increased by reviewing it.

2) Are there any charging tips or tips in general for cold weather? Will the pack charge under 32 degrees?

My 10 kWh Voltronix pack was installed in 2014 and is still functioning well. I do not keep it plugged in; I charge it and use it until the battery is at about 30% (according to the SOC ribbon indicator) then charge it again. The BMS will reduce or prevent charging depending on the temperature of the battery cells. I have found that if our Ranger EV Li is in an insulated garage the temperature seldom gets below 40 F even when it is below 20 F outside. Charging is impacted at about 50 F. You can use the vehicle in cold temperatures but charging might be an issue. The battery pack does "heat" up as it is used so one strategy is to use it before starting to charge. Again, if the temperature is not right the BMS will not turn on the Delta-Q charger, or will allow only low current, so no harm. If you can keep the Ranger EV Li in an insulated garage these issues are much reduced. Even an un-insulated shed is better than parking it in the open. Also, remember the temperature that matters is in the battery pack where the sensors are mounted; it is not a reference to the ambient air temperature. Please do post your progress as we will all learn something from your experience.
Thanks for the info Jack - its a cabin so no garage, the EV stays under the porch out of the elements - but I had thought the same as what you said, to charge it after using it when it would warm up, w longer range this sb doable - with the lead acid I basically plug it in after every ride to leave at 100% but I know the strategy is diff for Li-ion.
 
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