SR to ER battery swap DIY project

[TaxmanHog]

I don't see why DC fast charging would change. It bypasses the onboard AC charger(s). I've only ever DC fast charged twice and that was to test the Tesla adapter and the electrify america app.

I don't disagree, simply stating that I'd like to know that all is good and the rates of DC charge are not negatively affected.

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[zkeith]

Not sure yet what I'm going to do with the old battery yet. I may make a science project out of it.

That's the onboard chargers, and inverter. Now to setup microcontroller / canbus controller to see if I can manage to get these modules running standalone for my camper.

@kdcool with your battery pack ebay purchase, did you also get the onboard charger and inverter? I do see you mentioned that in previous posts, just wanted to be certain. Did you replace all those SR components with their ER ebay replacements? Not sure about others, but I am curious to hear more details. Also more pictures.

 

[Grumpy2]

@kdcool your efforts has significantly increased our knowledge of what is possible. Thanks!

Yet so many questions ...
The voltages of the two batteries were the same?
The locations of the cooling system were the same?
No fordpass changes to make the entire truck act "normal"?

Regardless, this certainly increases the value of a wrecked truck.

 

[shoopg]

@kdcool your efforts has significantly increased our knowledge of what is possible. Thanks!

Yet so many questions ...
The voltages of the two batteries were the same?
The locations of the cooling system were the same?
No fordpass changes to make the entire truck act "normal"?

Regardless, this certainly increases the value of a wrecked truck.

The voltages are different but close enough (~360v vs ~370v) that it doesn’t make a difference. The battery pack housings are the exact same between all 3 packs so yes the coolant and electrical connections are the same.

 

[BhamDCam]

@kdcool your efforts has significantly increased our knowledge of what is possible. Thanks!

Yet so many questions ...
The voltages of the two batteries were the same?
The locations of the cooling system were the same?
No fordpass changes to make the entire truck act "normal"?

Regardless, this certainly increases the value of a wrecked truck.

Hmmm, I hadn’t thought about FordPass changes. FordPass capabilities are tied to the VIN, so even though the truck recognizes the extra range, does FordPass? I’m assuming if you tell the truck to charge to 100% through the app then it would know to do that since the truck recognizes the larger battery…?

Interesting to think about. But I’m probably overthinking it.

 

[BennyTheBeaver]

Think of what this opens up for SR owners in need of a new battery. Nicely done!

 

[flux capacitor]

So there is a 8yr warranty on the battery what happens when one or two battery modules have a mismatch voltage issue how are you going to take care of that? Will Ford honor the warranty with the Vin says it is a SR? Or you are now on your own? Back to searching eBay for another ER battery.

The first month I got my 23 ER I had that problem of one battery module and it took 2mos to get that one module replaced.

 

[PJnc284]

I would think all bets are off and you're on your own for anything battery related.

 

[kdkool]

@kdcool with your battery pack ebay purchase, did you also get the onboard charger and inverter? I do see you mentioned that in previous posts, just wanted to be certain. Did you replace all those SR components with their ER ebay replacements? Not sure about others, but I am curious to hear more details. Also more pictures.

No I just did the battery. No other changes.

 

[kdkool]

@kdcool your efforts has significantly increased our knowledge of what is possible. Thanks!

Yet so many questions ...
The voltages of the two batteries were the same?
The locations of the cooling system were the same?
No fordpass changes to make the entire truck act "normal"?

Regardless, this certainly increases the value of a wrecked truck.

No coding. Ford pass works just like before. Yes same electrical and coolant lines. Literally plug and play.

 

[NW Ontario Ford Lightning]

All the batteries are made by SK, including his new one. Maybe the only thing to know and record is the mileage of the replacement battery doner and your mileage at the time of installation.
Meanwhile - yeah, I can't see swapping my SR pack out of the truck prior to the warranty running out on it first.

Keep the SR pack - it can be used with a solar set up as it is, AND it has all the spare battery packs inside you could ever need in the future if the new ER battery ever needed one and you had no warranty to fall back on.

 

[kdkool]

So there is a 8yr warranty on the battery what happens when one or two battery modules have a mismatch voltage issue how are you going to take care of that? Will Ford honor the warranty with the Vin says it is a SR? Or you are now on your own? Back to searching eBay for another ER battery.

The first month I got my 23 ER I had that problem of one battery module and it took 2mos to get that one module replaced.

I still have my original battery to revert back to should this ER battery croaks. The ER battery is definitely not warrantied.

I am not afraid to tear into the battery for a module or cell replacement if need be.

 

[kdkool]

All the batteries are made by SK, including his new one. Maybe the only thing to know and record is the mileage of the replacement battery doner and your mileage at the time of installation.
Meanwhile - yeah, I can't see swapping my SR pack out of the truck prior to the warranty running out on it first.

Keep the SR pack - it can be used with a solar set up as it is, AND it has all the spare battery packs inside you could ever need in the future if the new ER battery ever needed one and you had no warranty to fall back on.

Actually the cell configuration between ER and SR modules aren't the same. Refer to post 72. The flash configuration is closer to the the ER.

The SR battery pack is not ready for a solar setup as it is. Will need to talk to the internal BMS to activate the HV contact solenoids at minimum. Would also need a MPTT / charge controller that'd operate at the nominal ~350V as well as an inverter. Hence why I picked up the a lightning inverter and charger. I don't really care for solar as I have minimal roof real estate on the camper. I'd just level 2 charge it before I go boondocking. The expectation is that I'd run out of water well before I run out of power even if I had to run the campers rooftop AC for days.

 

[NW Ontario Ford Lightning]

The smaller pack in the ER battery is the same as the regular packs in the the SR, and in the case of a failure, out of warranty - better to have any pack then none at all...

I have thought about putting an EV battery pack between the frame rails of an RV travel trailer for similar set up. Agreed there is not enough roof area on an RV for solar panels - however using a battery pack with a home solar setup is an option.

 

[MountainAlive]

Well this is officially the coolest thing I’ve seen done on this forum. So surprised it just worked without any programming. Kudos to Ford engineers if that’s the case.

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