Under the hoodThe rear endE-Meter installationRefueling...Motor bolted to gear boxAC distribution box
OwnerThomas Everth
LocationCoromandel, Coromandel New Zealand map
Email email image
Vehicle1990 Toyota Starlet
conversion for local driving (90% of my rides) in the Coromandel township.
MotorD&D Motor Systems, Inc. ES-32A-50 Separately Excited DC
Got this through Thuderstruck WebPage in California.
DrivetrainManual gearbox, front drive, 5 gears
ControllerSevcon PowerpaK
DC Controller with regenerative breaking, throttle and break potentiometer and electric reverse/forward switch.
Purchased through Thuderstruck WebPage in California.

June 2009: The controller blew up after about 9 month in service when driving up a light incline and pulling about 240Amps. No external problems visible and the controller passed its self test (green light) but the controller is not starting. When removed from the car I can hear lose debris sloshing around inside, pointing to an internal explosion of some kind.
Sevcon, the maker of the controller, is denying warranty cover!!! Be careful with this crowd! While this controller worked well as long as it did, the fact that they are not honoring their warranty is a shock. Perhaps this is just because I am in New Zealand and to far away from the UK to cause them legal trouble. Who knows. But I do not think that this is a smart business move!
Batteries6 Trojan T-1275, 12.00 Volt, Lead-Acid, Flooded
150 AH deep cycle 12 Volt. Pack weight about 222Kg

System Voltage72 Volts
Charger Wellforces, Auckland
Bought 3 chargers at 24V 12.5A for about $150 each. Friendly company. Made in China I believe but looking good.
Site: WebPage
HeaterHat and mittens...!
DC/DC Converter Wellforces, Auckland
DC/DC converter 72 to 96V in, 12V 30A max output used to top up small 12V auxiliary battery.
Site: WebPage
InstrumentationE-Meter from Able Solar, Auckland
Top Speed50 MPH (80 KPH)
Reached 80 Km/hr on last test drive in 3rd gear.
AccelerationJust like before to 60Km/Hr then a bit slower.
Range20 Miles (32 Kilometers)
First test of full battery discharge was 20 miles. But on the same drive I also repeatedly went for max speed and had a few climbs. So actual range at 35MPH on flat land should be a lot better.
Watt Hours/Mile400 Wh/Mile
Used 90KWhr AC charging for 400Km. That is 0.24 KWhr / Km or 24KWhr per 100Km or at NZ power prices of about NZ$0.16/KWhr that is NZ$3.84 / 100Km of driving.
EV Miles
Current:3,500 Miles (5,631 Kilometers)
 
    As of 2/1/2010
Seating Capacity4 adults
Curb Weight2,028 Pounds (921 Kilograms)
After conversion = 920Kg total
Front Axle = 530Kg
Rear Axle = 390Kg

Before conversion = 840KG

Weight gain = 80Kg


Tires4
Conversion TimeMany days so far....
Conversion CostAbout NZ$11,000 including the base car, a $2100 Trademe purchase.
On Fuel savings: 100Km in the base car at 6L/100Km at $2 per Liter = $12 for fuel. Now: About 20Kwhr charging per 100Km at $0.16/KWhr = $3.20 or a saving of $8.80 per 100Km or 75%.
At 15,000 Km / year the savings are $1320, a return on my investment of well over 10%!
Additional FeaturesRegen breaking, 3 batteries under hood, three in battery well sunken where the spare wheel once was. Will carry no spare wheel.
Had more extended test voyage today! Works like a charm!
Have seen up to 400Amps on acceleration. Got up to 80Km/hr.
Made it back up our steep drive (15Deg) easily.
Great fun!
Regnen braking is great just with throttle in idle.

I fitted a relay to the break light that switches the controllers regenerative breaking mode to a high setting. Ideal! With the foot of the accelerator the car slows like a petrol car with the engine breaking, and when the break light comes on with a lightly depressed pedal the car slows a lot better. Great for rolling down hills.

Careful with the Sevcon Company. My controller failed after only 9 month in service with an internal explosion inside the controller but Sevcon will not honor their warranty!!! Probably better to look for a company that deals ethically. Unfortunately SEM controllers are hard to find.


code by jerry