First I had to take all the cells apart when you get them apart as you can see lots of little nuts... and connectors so I will have to have the connectors drilled so I can use them in the connections of 6 cells that I have decided to do .........

tonights work was installing the contactor box assy. and hooking up the hi voltage cables from contactor box assy to pack plus and pack minus  ................



adding the lower side wires for the orion system to be able to control the cells ...........

I have these custom made connectors to hook the packs together instead of the original connectors these I can hook with standard cables ....

Cleaned up the pack and removed everything to make it clean and ready for some risers ....

First section put into place fully equalized and bottom wired and sealed ......

2nd section is placed into the pack and getting ready for more sections this is the part that takes a long time charging and equalizing before wiring and placing into the pack .......

added the risers to the rear section of the pack to get it ready for the enerdell packs when they are done

I did the updates to bypass the relay and move the negative charge wire on contactor to allow the new charger a 5kw elcon to be controlled by the orion and can controlled .........................

above is the wiring diagram to wire by .....

I used the power 12V+ from #14 from the bcm

it is power when key is on or in start position

#17 is the wire from bcm that is circuit #3705

I don't use the charger door I use the 12V from the key on instead ....

First unit is put together ....need to use the power lab units and equalize all the cells to start exactly the same so I charge each and every cell to exactly 4.1V before I put them in the pack sealed up .......

I have now finished all the cells and wired in the cells for the bms orion assy.  a wire to each cell so it can monitor and easily balance the cells every charging cycle keeping them in the bes shape they can be kept in ....

finally I have all the cells equalized and assembled and installed in the pack ...  next step is installing connectors and wiring it up ... to the orion ....

starting to add the connectors to the first pack ... they are time consuming but the end result is great ....

here it is installed in the pack

this is the regular wiring for a db9 to obd2 connector

I need to wire up the can high....can low.....chassis ground .... and battery power 12v+  I did this and installed it by drilling a hole in the side of the pack and I hang it out so it can be easily with a db9 male to female adapter just plugged in then ran up under the hood to be attached to the new can elcon 5kw charger to be installed under hood it is can controlled I will also add a wireless Bluetooth system to hook with a new stereo system in the dash and a j1772 charging system but I get ahead of myself ....  the db9 system first ...

all the orion wiring is of course at orionbms.com so if you have questions feel free to go to their website and download their wiring manual when you install a orion system ......

sealed the wiring and ready to lay it into the pack

all wired up to orion assy and spoof boards etc.

next is the newest board that is a amp increaser to fix the gauge problems I have always had with these trucks

First things first so I have already took all the cells and separated them and am ready to start assembling them into their respective packs I will get that done first and post some picks I am still waiting for the vehicle so I am going to get ahead of the game a little by getting these ready to assemble ....

added high voltage last cables to pack so all high voltage cables are now done ....

Knock all the metal hold downs off the lid because they are not going to be needed for the new batteries and get rid of them ...

Made a quick wiring diagram for wiring up the orion to the new pack and am doing that today ....

laying down the first section and getting it ready to start putting the connectors on ....

Ranger EV Enerdell 105 AH pack

This is a 105AH enerdell cell pack ...  of course as usual remove the pack clean it all up and get it ready to install the new cells ....  These are enerdell energy cells 17.5AH each cell I am putting 6 in parallel to get 105AH then putting 90 of them in series to get approx. 368V when full ......................  I am making 5 even assembly packs so they can be interchanged and makes for easier assembling of the main pack ......  I will be assembling 54 segment  modules that's 108 cells in each assembly ..................... it comes out to 18 (6 cell) assemblies ....   here is my beginning sheet schematic for putting the pack together ......

above is 1 section the front connectors ready for wiring  that's my next step I will be starting that part to continue the installation ....

Starting the last 2 steps installing the orion and installing the blocking to hold the module packs into solid place ...

next step I separated the cells and stacked them into 5 stacks with 105AH alternating cells to start assembly

I will pick up some 5/16" ready rod and will assemble these 5 stacks with 4 rods each to make them a strong set .....

not to forget a important part of the install is to wire up the spoof board to make the bcm from the truck happy the spoof board basically takes the pack voltage from plus and minus of the pack and in this case divides it into 39 perfect inputs so the truck is happy and thinks all the batteries are perfect and in good shape since our bms the orion is what takes care of the charging and pack voltages and equalization every charge we don't need the truck to try and do the same thing since the orion does more then the truck originally can do to protect the new lithium cells as it was really only designed for either lead acid or nickel metal hydride batteries ..... so here is the wiring from the manual and the spoof board and the cables cut off and removed from the wiring of the original pack

and above is the finished db9 assy. at the very end under the hood as orion instructs I will add the 120 ohm resistor so the can controlled charger and the wireless system can both work together while driving and while charging ........

Wired up and added covers now to tape them down

This is the timer board assy. I have found them on ebay and on amazon if you are looking for them I added a 60 ohm resistor to this one you can use a adjustable pot but I will try this size first ....

Picked up a bunch of 5/16" ready rod and assembled the packs together with them so I can move them around while connecting and wiring them so this step is important and this is how they look after connecting I cut the excess of and stack them back where they began ....

In the front section I add the risers to raise the cells up off the bottom of the case ...  I use a stuff called amazing goop that holds pretty much anything to the case that I want .......

now the pack is wired and ready to test last thing is to install the db9 for accessing and installing the program in the orion

and as you can see all wired up and placed back into the pack I will wire tie it and glue it into place so it will be ready to use ..................................

and finished and set aside for assembling later ....