SR/ER number of pouches, cells, battery modules, starting with ChatGPT

[TaxmanHog]

@TaxmanHog @Grumpy2 @MickeyAO @jmc6020
Finally I found, looking at this Safety Recall 24S11 for some re-torquing of HV bus bars of 200 Lightnings, Figures show different size HV battery modules for the SR vs the ER. This makes me think that @Ford Senior Master is correct on the SR using 9 smaller size Aluminum housings. Since the ER small module sticker shows 11.95kWh, 9 x11.95 is 107.55 kWh, this would match the overall SR battery pack sticker! So this would probably mean both the SR and ER cells are made up of the 5 pouches, but the SR only has 9 x 8 cells = 72, whereas the ER has the 96 cells. 96/72=1.33 ratio that matches the ER/SR battery output ratio of 131/98. Final answer? Using smaller modules would help account for the extra payload capacity of the SR trucks.
I just need someone to show that there are only 72 cells for an Standard Range battery pack to feel good about this as we have seen the 96 cell listing for the Extended Range battery pack.

from a forum member photo of the ER small battery module #9:

Another forum member had this shot of the Standard Range battery pack 107.6 kWh rating.

Those values make sense, Ford lists four distinct part numbers for modules on 2022 SR & ER trucks
These could be variants of module shell sizes with the various counts of pouch/cell groups as outlines in post #30

2022 SR
FRONT NL3Z-10D672-H
Rear NL3Z-10D672-G

2022 ER
Front NL3Z-10D672-F
Rear NL3Z-10D672-E

TASCAPARTS.COM does not list the 2025 parts for any version as of now.

 

[GoodSam]

New configuration battery for the mid-range.

I am surprised at the complicated setup...my simplified explanation, with fewer module variations, would have been better! I see the ER 5p96s 5x96=480cells, divided by the SR 4p90s 4x90=360cells is the 1.333 ratio for kWh storage capacity difference. Thanks for the inside information!

 

[Firn]

Do SR trucks really have a lower system voltage?

That would explain the lower horsepower and slower charging

 

[TaxmanHog]

Do SR trucks really have a lower system voltage?

That would explain the lower horsepower and slower charging

Six fewer cell groups in series implies that as a fact.
Then one fewer cell in parallel is reducing capacity {kWh}

 

[Firn]

Six fewer cell groups in series implies that as a fact.
Then one fewer cell in parallel is reducing capacity {kWh}

It does imply it, hence the question. This is the first I have heard that the two trucks run a different voltage.

 

[PJnc284]

New configuration battery for the mid-range. Each cell is still 3.7 volts. I was expecting LFP for 2025. Maybe we will get it mid year.

I'd be surprised if you see LFP before Ford gets their US plant built (supposedly next year).

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