BMS/contactor questions on Polaris Ranger EV lithium conversion

FlintHills

10 µW
Joined
Aug 10, 2024
Messages
6
Location
Kansas
Greetings, all:
I'm building a 16S 48V pack with 230Ah EVE cells to replace a dead FLA pack in a 2014 Polaris Ranger EV. I thought the 200A JBD BMS I ordered would work, because it's rated for 600 surge amps. But folks over at DIYSolar Forum are cautioning me against allowing FETs to pass so much current to the existing mechanical contactor, which I'd like to retain.
I can't say what a typical usage load is, as I bought the craft with dying batteries, but the controller is a 650-amp Sevcon Gen 4 with regen braking. So, pretty thirsty.
There was a suggestion to use a Chargery BMS
chargery model power, specially design the equalizer, smart balancer and lipo balancer for R/C model
Its description mentions accommodating regen braking and a 600A draw, but with my limited/nil experience, I can't determine whether this is a solution.
Thanks in advance.
Andy
 
Seeing as I've come this far with these parts, I think I will throw a T-1 fuse in there, install it and see whether the BMS trips in usage, then upgrade as needed.
 
What is the voltage of the coil on contactor? if the coil is 48V you could use the JBD negative load wire to power the coil and bypass the bms for the load. Or you could use a buck converter to lower the Voltage from 48V to 12-24V to power the coil. The only thing you lose is over current protection all other protections would still be there.
Later floyd
 
Thanks, Floyd. Yes, it is a 48V contactor. I'm a wiring idiot, so I will have to have the BMS and the contactor in front of me to see how that would go together.
 
Hello sir, you have some bms that use a contractor and not fets. On AliExpress you can find some of this models.
Thank you for the suggestion. Yes, I have heard of Chargery and others. Amy Wan at Luyuan suggested I email Jason to inquire. I want to re-use the existing mechanical contactor if possible.
 
if the coil is 48V you could use the JBD negative load wire to power the coil and bypass the bms for the load.
Two No. 4 AWG cables come out of the BMS, at terminals marked C- and B- . I've looked over the JBD spec sheet, but it's only about settings, not wiring. The balance leads, I've figured out, but not the high-amperage stuff.
I'm including a link to photos of the BMS and the existing Polaris contactor and controller. I'm still unclear on how to execute Floyd's suggestion.
Thanks again.
 
The cable from the bottom of the contactor connects to the fused B+ on the controller, by the way. The open blue-bordered connection staring at the camera is the so-called MPC, main power connector.
 
The contactor appears to be controlled by the motor controller so my suggestion won't work without adding at least one more contactor.

Later floyd
 
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