Jon Arne Pettersen

Her at 19:58

My project will battery cost around 2000$ with bms and a new charger 60 amp cost 250$ I'll do all y work my selve. I'll try to sell the original battery pack

Hello, interesting reading all your projects. Her is mine. I just bought a "new" 2023 model with only driven 10km Her is my project 😊 I hope I can get some feedback on this 👍 Hisun Sector E1 — 19S LiFePO4 Upgrade Summary Vehicle: Hisun Sector E1 UTV (original 48 V lead-acid version) Goal: Replace lead-acid pack with high-energy 19S LiFePO4 system to increase speed, efficiency, usable power and cycle life, while staying within safe limits of the Sevcon controller and drivetrain. Battery System Chemistry: LiFePO4 (LFP) Configuration: 19S1P Cells: EVE LF280K class (nominal 280 Ah, measured ~305 Ah batch) Nominal cell voltage: 3.2 V Nominal pack voltage: 60.8 V Max charge voltage: 3.60 V/cell → 68.4 V pack Occasional top balance: 3.65 V/cell → 69.35 V pack (not daily) Low-voltage limit (daily): 2.8–2.9 V/cell Emergency cut-off: 2.5 V/cell Capacity: ~19 kWh usable (19 × 3.2 V × 305 Ah ≈ 18.5–19 kWh) Peak discharge: >600 A capable (limited by controller and cabling) Continuous discharge: ~300 A typical use Power Electronics Motor controller: Sevcon Gen4 Size 4 (LV) Nominal voltage limit: ~69.6 V Peak allowed slightly higher with internal cutback Measured operating current: Acceleration: ~300 A DC Cruise at top speed: ~120–140 A DC Peak mechanical power: ~18–20 kW estimated Top speed increase: from ~45 km/h (48 V lead) to ~55–57 km/h at 19S Charging Charger: Adjustable 67–84 V LiFePO4 charger Daily charge setting: 68.4 V CV Charge current: 30–40 A normal, up to 60 A occasionally Termination: current taper, no float Temperature compensation: disabled (LFP chemistry) Connector: Type 2 inlet used purely as 230 V AC connector (no EVSE / CP signalling) BMS & Safety BMS: ANT Smart BMS, 19S Contactor: ≥300 A DC rated, 12 V coil Precharge resistor: 100–300 Ω, 20–50 W Main fuse: 400 A slow-blow (optionally 450–500 A) Cabling: Drivetrain: 35–50 mm² copper Charger: 16 mm² 12 V system: 6–10 mm² 12 V System DC/DC: 30–100 V → 13.8 V, 50 A isolated converter Buffer battery: 12 V 80 Ah gel battery Purpose: transient buffering, redundancy, stable 12 V rail Cooling Custom evaporative spray cooling on controller heatsink (washer fluid spray) Maintains controller plate temp ~60–70 °C under heavy load Motor and gearbox remain below 50 °C Spray only active above ~15 °C ambient Key Observations Induction motor explains high startup current and relatively low cruise current. Voltage, not controller limits, is the main determinant of top speed. Lithium reduces voltage sag dramatically versus lead-acid, improving both acceleration and sustained speed. 19S is the practical upper limit for this Sevcon platform without going into HV variants. Summary The 19S LiFePO4 conversion transforms the Hisun Sector E1 from a low-performance utility platform into a high-efficiency, high-power electric drivetrain with significantly improved speed, torque, range, and thermal stability — while staying within safe electrical and mechanical margins. This setup prioritizes: Long cycle life Electrical safety Thermal control Serviceability Real-world reliability over extreme peak performance

What speed are you getting, before and now?