Electric Polaris Ranger

[John_Mc]

I'm curious what the manufacturer recommended on battery usage. For regular lead-acid you never want to go below 50% charge (not to be confused with 50% of full voltage), and you do not want to leave the battery in a partially discharged state for an extended period. For Nicads, you had to make sure to cycle them all the way down occasionally, to prevent memory effect.

My understanding is that Lithium Ion has none of those problems. There is no need to occasionally discharge it all the way, thought you can do that without damage, if you wish. (About the only downside to discharging all the way is the time it takes to bring it up to full charge again). They do say its good to actually use them from time to time: draw electricity out, and recharge them.

About the only odd-ball thing I've heard about Lithium Ion batteries is that if you will be storing them for an extended period, it's best to store them partially charged (about 50%). This is something I don't hear mentioned very often, but I've started doing it with my cordless tools. Did the documentation with your new batteries say anything about long-term storage?

 

[Xfaxman]

They recommend 30%. If you go too low the Battery Management System will turn off the power to the contactor that connects the battery pack to the motor controller. I don't know what that too low setting is and hope I don't find out a mile from home.

It took just over 10 hours to recharge from 15%.

The only documentation received was the conversion manual, it didn't cover long-term storage, but I think 50% would be a good idea.

 

[vvanders]

They recommend 30%. If you go too low the Battery Management System will turn off the power to the contactor that connects the battery pack to the motor controller. I don't know what that too low setting is and hope I don't find out a mile from home.

It took just over 10 hours to recharge from 15%.

The only documentation received was the conversion manual, it didn't cover long-term storage, but I think 50% would be a good idea.

Anything under 90% should be good. Our EV has stayed at 90% when we aren't driving it for the last 2.5 years and it's only lost about 3% total range.

You don't want to leave it at a 100% SoC(unless the BMS has a "buffer" that they hide as 100%) for more than a few hours. There's two things that Li hate, heat and sitting at 0% or 100% SoC. Anything > 10% and < 90% is totally fine.

 

[John_Mc]

You don't want to leave it at a 100% SoC(unless the BMS has a "buffer" that they hide as 100%) for more than a few hours. There's two things that Li hate, heat and sitting at 0% or 100% SoC. Anything > 10% and < 90% is totally fine.

Agreed. While one manufacturer recommendation said 50%, others have said "mid-range charge" or words to that effect. I don't like to store any battery at 0% (can be more of a freeze concern at low state-of-charge). I just shoot for "somewhere in the middle" and don;t worry about hitting 50% exactly (or even close). My cordless tool batteries only has 4 lights indicating charge, so I shoot for 2 or 3 lit up.

 

[Xfaxman]

You could pull a trailer (or two). I think the EV will out pull any other UTV, due to it's power and weight.

The red tilt trailer scaled 1660 on the tires, not much tongue weight. so I don't know the total weight.

Never weighed the other one, but the EV pulls them easily.

Still running on the second charge, showing 70%.

Reference these earlier posts, I checked the tongue weight:

Zeroed the scale with the chains on it and picked up the trailer to get total weight:

Now I will have to weigh the yellow trailer.

 

[Xfaxman]

Now I will have to weigh the 5x9 yellow trailer.

Weighed it, but it will be heavier after I replace the deck and fenders:

Checked the tongue weight:

So the EV was pulling 2,549 pounds, slightly over the Tow Rating.

 

[Xfaxman]

Time for the third full charge of the Li-ion batteries. Showing 187.2 hours, means 2.5 hours since the last charge 27 days ago. The State Of Charge meter is showing 20%:

Started yesterday at 1:15pm. Stopped it at 6:45pm.

Started today at 10am, at 10:20, SOC was 79%:

95% at 11:48am:

After lunch, instead of turning the key on to see the Charge Status Indicator, I hooked 12 volts to the constant current terminal. It worked, the Charge Status Indicator was still flashing fast:

Ammeter at lowest level, Bulk charge phase complete:

2:45pm Charge complete, both green lights on solid:

Third time charging was successful. :thumbsup:

 

[Xfaxman]

Time for the third full charge of the Li-ion batteries. Showing 187.2 hours, means 2.5 hours since the last charge 27 days ago. ---------------------------------------------


After lunch, instead of turning the key on to see the Charge Status Indicator, I hooked 12 volts to the constant power terminal. It worked, the Charge Status Indicator was still flashing fast:

View attachment 523185

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Third time charging was successful. :thumbsup:

After I used the battery to power the Charge Status Indicator, I remembered that Voltronics added a 12vdc power supply to power the BMS while charging the batteries:

So I looked through my used wire box and found wires with spade lug connectors to try using the 12vdc power supply to also power the Charge Status Indicator, since it only draws 53ma and the BMS is on a 5a fuse and draws about 118ma.

I added a piggyback spade lug connector wire to the fuse block where the 12vdc power supply plugs in, ran it through a 2a fuse, to the constant power terminal:

Plugged in the charge cord and got 12.6 vdc on the constant power terminal:

It worked, the BMS is on, the DeltaQ was charging and the Charge Status Indicator, was flashing. :thumbsup:

For those who haven't seen a piggyback spade lug connector to put two wires on one spade lug:

 

[Xfaxman]

Where I piggybacked is the output of the Voltronics 12vdc power supply, it is feeding back in from the constant power terminal, through the 2a LSV fuse to where the Charge Status Indicator is hooked to the old constant power wiring.

I later found out that since the power supply was off but still connected, the LSV fuse blew when I turned the key on. I think the output filter capacitor in the power supply drew more than 2 amps from the converter, blowing the LSV fuse.

I temporarily used a bigger fuse and tried it several times, everything worked OK.

The easiest thing would be to run a wire from the power supply to one of the fused +12v Batt wires under the seat, because they have a diode that would prevent the back feed from the converter.

But I would like to find the diodes, because it might be a shorter, easier wire run:

 

[Xfaxman]

Re: Electric Polaris Ranger---Conversion To Lithium-Ion Batteries

Here is where I removed the OEM State Of Charge meter or as Polaris calls it, Level Of Charge meter: http://www.tractorbynet.com/forums/...c-polaris-ranger-post4831562.html#post4831562

I decided that I want the LOC back in the dash so the hour meter is visible. That means I will have to move the Voltronics SOC meter. Picked this location above the key switch:

Drilled the plastic dash, made it a slot and poked the connector through it:

Still had some double stick tape on the back of the SOC meter:

Put the LOC meter back in the original location, will probably disconnect the red LED battery level display, since it is not accurate with the new Li-ion batteries:

Now there are two "Of Charge" meters:

It is now much easier to see the green indicators on the SOC meter. :thumbsup:

 

[Xfaxman]

For reference powering the charge status indicator, read this and post #130: http://www.tractorbynet.com/forums/...c-polaris-ranger-post4886706.html#post4886706

The easiest thing would be to run a wire from the power supply to one of the fused +12v Bat wires under the seat, because they have a diode that would prevent the back feed from the converter.

Could not find either diode, so I did it the "easy way". Used some small tubing to protect the wire coming from under the hood to under the seat:

Poked the wire into the tubing and pushed it through:

Spliced to the pink 12v bat wire that was on the first deep cycle battery in the series string:

Slid the covering back over to the fuse holder and put it back up out of the way:

The Voltronics power supply is only on when charging the battery packs:

It now puts it's DC voltage through a diode to the constant power wiring system causing the Charge Status Indicator to operate:

 

[Xfaxman]

It has been about 20 days since I charged the Voltronics Lithium-ion batteries, the SOC was showing 40%:

And 189.3 hours:

Screen shots from before plugging in the charger, Pack voltage is 52.4 volts:

Right click this one and open in new tab, to see it better

Plugged in the charger at 10:30, the Charge Status Indicator started flashing, my wiring modification is working!

Came back after lunch, SOC is up to 64.5%, 17.2 amps going into the batteries. Pack voltage is 54 volts:

Just over 8 hours charge time, the Charge Status Indicator is on solid:

Pack voltage is 58.7 volts:

Fourth time charging was successful.

 

[JRobyn]

Yikes! 58.7v? Any chance that the Sevcon and the motor will disagree with that high a voltage?

 

[Xfaxman]

No the motor runs on three phase AC, produced by the Sevcon.

Voltronics modifies the DeltaQ charger and the Sevcon motor controller, so there shouldn't be a problem.

 

[Xfaxman]

Re: Electric Polaris Ranger, Charging the Lithium-ions again.

It has been over three weeks since I charged the Voltronics Lithium-ion batteries, the relocated SOC meter was showing 2 bars:

And 190.6 on the hour meter, nice to have it back in the dash:

Screen shots with just the BMS powered, before plugging in the charger, Pack voltage is 52.5 volts SOC is 17.5%%:

Right click the above picture and open in new tab, to see it better.


Plugged in the charger at 11:20 am, the Charge Status Indicator started flashing, my wiring modification to power it is still working!

The Delta-Q charger is flowing 17.2 amps:

Went out at 5:30 pm, ten bars on the SOC meter and the Charge Status Indicator is on solid:

And the green light on the charger is on solid:

Pack voltage is 58.7 volts and no charge current flowing:

More information overload from the BMS program:

Fifth time charging was successful. :thumbsup:

 

[Xfaxman]

--------------------

I decided that I want the LOC back in the dash so the hour meter is visible. ---------------------
--------------------------------

Put the LOC meter back in the original location, will probably disconnect the red LED battery LOC, since it is not accurate with the new Li-ion batteries:

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Checked the wiring diagram:

Unplugged it and pushed out the three connectors for the Level Of Charge meter:

Put rubber tubing over the connectors and taped with electrical tape and plugged it back together:

The key is on and the red LOC LED is off, yea!:

Now it is just a Hour Meter, yea!:

 

[Xfaxman]

It has been two weeks since I charged the Voltronics Lithium-ion batteries, the relocated SOC meter was showing 2 bars again, just like last time:

And 191.4 on the hour meter

So yesterday after the modification to the LOC meter I unplugged the charger from the Y connection and plugged it in to turn on the BMS. Got a picture of the status before charging:

Plugged the charger into the Y connection at 3:05 pm. Went out at 9 pm, the Charge Status Indicator was flashing slow, meaning over 80% complete. While I was looking at the BMS data, the CSI went solid green, meaning charge complete:

Sixth time charging was successful. :thumbsup:

 

[Xfaxman]

It was two and a half weeks ago that I charged the Voltronics Lithium-ion batteries, the SOC meter is showing 2 bars again, just like the last two times:

And 192.8 on the hour meter equals 1.4 hours of actual run time, mainly going to the mail box and back:

So yesterday I unplugged the charger from the Y connection and plugged in the cord to turn on the BMS. Got a picture of the Live Params before charging, showing pack voltage at 52.5 volts equals 15% SOC:

This shows the voltage of the 16 cells in the pack:

Plugged the charger into the Y connection at 11:20 am, to start charging. Checked the BMS at 1:17 pm, the SOC is up to 34.5%, charge current is 17.4 amps:

Went out to the garage at 7:20 pm, ten bars on the SOC meter and the Charge Status Indicator is on solid, meaning charge complete:

Pack voltage is 58.8 volts and no charge current flowing:

Seventh time charging was successful. [/COLOR][/COLOR]:thumbsup:

 

[Sysop]

Very cool. I'm about to take the plunge on one of these RangerEVs. Hopefully before spring.

Are you going to post results for each of the 3000 charge cycles those batteries are supposed to be good for?

 

[Xfaxman]

Very cool. I'm about to take the plunge on one of these RangerEVs. Hopefully before spring.

Prepare to be amazed. :thumbsup:

Are you going to post results for each of the 3000 charge cycles those batteries are supposed to be good for?

Got to do something to keep the thread active!

As the weather gets colder, I will just plug it in and let it charge without connecting the BMS to the laptop. Sure is nice to have the Charge Status Indicator working now after my wiring modification.