How to Choose the Suitable Lithium Battery Pack for the Electrification Conversion of Wuling Journey MPV? (339.2V 230Ah, CCS2, EVCC)
Electrifying the Wuling Journey MPV involves replacing the internal combustion engine with a high-performance electric powertrain. A critical component in this transformation is the lithium battery pack, which serves as the energy source for the entire system. Based on the 120kW 3-in-1 powertrain specifications, selecting a 339.2V 230Ah lithium battery pack with CCS2 charging interface and EVCC (Electric Vehicle Control Communication) capability is highly recommended. Here’s a comprehensive guide to making the right choice.
- Voltage Compatibility: Match the Powertrain Platform
The 3-in-1 powertrain operates on a 385V DC nominal voltage platform, with an operating range of 290V to 480V. A 339.2V battery pack (typically 96–100 cells in series, depending on cell chemistry) falls within this range and ensures stable operation. It provides sufficient headroom for voltage sag during high-load discharging while avoiding overvoltage damage. Confirm that the battery’s maximum output voltage does not exceed 480V under full charge.
- Capacity and Energy: Ensure Adequate Range
With a 230Ah capacity, the battery delivers approximately 339.2V × 230Ah = 78 kWh of energy (theoretical). This provides a realistic driving range of 300–400 km depending on driving conditions, load, and efficiency. This capacity balances range, weight, and cost—ideal for a mid-sized MPV conversion.
- Cell Chemistry: Opt for NMC or LFP
Choose between NMC (Nickel Manganese Cobalt) for higher energy density and better performance in cold climates, or LFP (Lithium Iron Phosphate) for longer cycle life, enhanced safety, and thermal stability. For daily use and safety, LFP is increasingly preferred, though it may require a slightly larger pack to achieve the same energy.
- CCS2 Charging Interface: Enable Fast and Standardized Charging
The CCS2 (Combined Charging System 2) connector supports both AC and DC fast charging. This allows:
- AC chargingvia a 6.6kW on-board charger (ideal for home or workplace)
- DC fast chargingat public stations (up to 50–100kW), reducing charging time to under 1 hour for 80% charge
Ensure the battery management system (BMS) is fully compatible with CCS2 communication protocols (e.g., ISO 15118, DIN 70121) for plug-and-charge functionality and safe high-power charging.
- EVCC Support: Enable Intelligent Communication
EVCC (Electric Vehicle Communication Controller) is essential for modern EV charging. It enables:
- Secure communication between the vehicle and charging station
- Authentication, billing, and remote monitoring
- Smart charging (e.g., schedule charging during off-peak hours)
- Over-the-air (OTA) updates for BMS and charging firmware
Ensure the battery pack or vehicle integration includes an EVCC module that supports ISO 15118-2/20 for seamless public charging network access.
- Battery Management System (BMS): The Brain of the Pack
A robust BMS is non-negotiable. It must:
- Monitor individual cell voltages, temperatures (using PT1000 sensors), and state of charge (SOC)
- Perform cell balancing to extend pack life
- Protect against overcharge, over-discharge, overcurrent, and short circuits
- Communicate via CAN buswith the motor controller, OBC, and EVCC
- Support real-time diagnostics and fault logging
The BMS should also support insulation monitoring (critical for high-voltage safety) and integrate with the vehicle’s existing CAN network.
- Thermal Management: Maintain Optimal Temperature
The powertrain is liquid-cooled, so the battery pack should also feature liquid cooling and heating to maintain cell temperature between 20°C and 35°C. This prevents degradation in extreme climates and ensures consistent performance. Confirm the pack has integrated thermal plates or cooling channels compatible with the vehicle’s cooling loop.
- Protection and Durability
The battery pack must meet IP67 or higher protection rating to resist dust and water ingress. It should be housed in a rugged, fire-resistant enclosure with crash protection and vibration damping. Given the vehicle’s design life of 20 years or 300,000 km, select a pack with a cycle life of at least 3,000 cycles (at 80% capacity retention).
- Safety Features
Essential safety systems include:
- High-voltage contactors with pre-charge circuit
- Emergency disconnect (manual service disconnect)
- Fire suppression materials (e.g., aerogel barriers)
- Venting system for gas release
- Insulation monitoring device (IMD)
- Physical Integration and Weight Distribution
The Wuling Journey MPV has limited underbody and cabin space. Design the battery pack to fit in the chassis or floor area without raising the center of gravity. Aim for balanced weight distribution to maintain handling. The pack should be modular for easier installation and maintenance.
- Compliance and Certification
Ensure the battery pack meets UN 38.3, GB/T, or IEC 62133 standards for lithium batteries. It should also comply with EMC and safety regulations for road vehicles (e.g., E-Mark certification).
- Manufacturer Support and Warranty
Choose a reputable supplier offering a warranty (ideally 8 years or 160,000 km), technical support, and software updates. Custom battery packs for conversions should come with full documentation and CAN database (DBC) files for integration.
In conclusion, the ideal lithium battery pack for the Wuling Journey MPV conversion is a 339.2V 230Ah unit with CCS2, EVCC, liquid thermal management, and a robust BMS. When properly integrated, it will deliver reliable performance, long range, and compatibility with modern EV charging infrastructure—transforming the Journey MPV into a safe, efficient, and future-ready electric vehicle.
