OwnerAllan Poulsen
LocationOttawa, Ontario Canada map
Web/EmailWebPage email image
Vehicle1996 Ford Ranger XL
MotorNetgain WarP 9 Series Wound DC
DrivetrainClutch & 5 speed standard transmission
ControllerDC Power Systems DCP Raptor 1200
Originally supporting up to 600A, this DCP Raptor was
updated to 1200A. Unfortunately this is no longer
Batteries48 Thunder Sky 160Ah, 3.33 Volt, Lithium Iron Phosphate
Actual brand is now called "Winston", previously called
"Thunder Sky". The pack voltage is typically 150-160V during
operation, and 160V during charging, rising to 175V at the
end of charge.
System Voltage160 Volts
ChargerElcon PFC2500
Elcon 2500W smart charger, 120/240VAC input, configured
for 48 cells (175V max), with miniBMS input for safety. Output
160-175V DC at 8A at 120VAC input, and 15A output at
208/240VAC input. Also have an old Bycan, 120/240VAC
input, configured for 144V DC nominal output (up to about
180V) and 8 to 16A output, with AC relays controlled by
miniBMS to shut this charger down for safety. Powerstat
variable transformer to reduce current draw by Bycan on
15A/20A 120VAC circuits. Also, Soneil 12V 5A charger with
240VAC input to keep 12V system happy and reduce DC/DC
converter draw during pack charging/balancing.
Heater2x1500W Ceramic for cab, 1x500W oil filled radiator for
batteries. Elcon charger and Soneil charger are also in battery
box so heat can be used in winter. Fans in battery box to even
out the heat distribution, and input and exhaust fans bring in
cool air and exhaust warm air controlled by a thermostat.
DC/DC ConverterGo Power GPC-45
45A 12V output.
InstrumentationBattery Amps and Volts, Motor Amps and Volts, miniBMS
display, and custom LEDs (12: 1 per 4 cell segment) that will
shut off if one of the cells fail.
Top Speed63 MPH (101 KPH)
100km/h (63MPH) is all I need. It can go faster now that it has
AccelerationMuch better now that it's 1000 lbs lighter with the lithium
pack instead of lead. Typically first off the line, and
acceleration is now reasonable overall.
Range50 Miles (80 Kilometers)
80km - Aggressive acceleration and braking, or higher speed
(100km/h, 63MPH) uses 2A per km in this truck. Driving more
conservatively brings the usage down to 1.5A/km, or even
less, making a range of 100km (63miles) reachable with
capacity to spare.
Watt Hours/Mile320 Wh/Mile
12kW @ 60km/h (37.5 MPH)
= 12kW / 60km/h
= 12000Wh / 60km
= 200Wh/km * 1.6km/mile = 320Wh/mile
(measured at the battery output)
EV Miles
Start:50,000 Miles (80,450 Kilometers)
Current:87,500 Miles (140,787 Kilometers)
Total:37,500 Miles (60,337 Kilometers)
    As of 10/23/2012
Seating Capacity5 adults (uncomfortable), or 2 adults and 2 kids
Curb Weight3,400 Pounds (1,545 Kilograms)
Dropped 1000 lbs when switched from 24 golf cart batteries
(225Ah) to 48 lithium cells (160Ah).
Tires50 psi rated light truck tires.
Conversion TimeAbout 200 hours of labour.
Conversion CostCDN$12k parts and $8k labour, not including batteries.
Additional FeaturesWinterized battery box (1" foam insulation on all sides), 500W oil filled radiator heater
(thermostat controlled) and chargers in the battery box, keeps batteries in good
temperature range in winter ( >20C, even when -35C outside!). Fans for cooling in
summer. MiniBMS balances and protects the lithium cells. Green electricity sourced from
Bull Frog Power WebPage . License plate "SPARKYEV". Power
steering, power brakes. 2 Extra leafs in rear suspension. Safety - 250 Amp breaker, 500A
fuse, dual contactors, momentum switch, Anderson battery disconnect, MiniBMS,
onboard breaker panel to distribute 240VAC safely to 2 onboard chargers. EV Plug inlet
(J1772) connector behind fuel door. Additional 120VAC inlets, switched to allow for
120VAC service when J1772 EVSE not available, one to each charger.
I am the second owner, bought November 2002. Converted in April of 2001 by original
owner Michael Anderson, and Rick Lane of REV Consultants (
WebPage )
Upgraded to lithium batteries in March 2012 by Rick Lane of REV Consultants, and CanEV
(battery and charger supplier - WebPage ).

code by jerry