|Location||Dublin, California US map|
|Vehicle||2001 Volkswagen Passat |
|Motor||Siemens Siemens motor built for Ford Ranger EV 3-Phase AC|
90kw water cooled 3 phase AC Motor
|Drivetrain||Stock 5 speed manual. |
I designed the motor coupling and adapter plate myself.
|Controller|| Tischer AC90 with torque control|
I built the 3 phase controller myself. It is running in
closed-loop vector mode, which allows control of torque and
My AC90 controller draws 300a @ 300vdc (330vdc pack with
some sag under load), about 120 hp.
Water cooled IGBTs
|Batteries||99 Thunder Sky 100 Ah LiFeYPo4, 3.00 Volt, Lithium-Polymer|
|System Voltage||330 Volts|
|Charger||Manzanita Micro PFC20|
If I can keep the charger cool, I can recharge at about 16 miles
per hour (26 amps @ 208 volts). The charger is only rated for
20 amps though.
|Heater||Heated leather seats. Ceramic heater core installed in the |
cabin air filter box.
|DC/DC Converter||Iota |
55 Amps at 13.4 with the ignition relay off, 14.3 volts with
|Instrumentation||The industrial inverter I am using came with a 2 line LCD |
key pad. It can display motor load, torque output, motor
amps, dc bus voltage...
-100 to 300 amp ammeter, I can peg it in both directions.
I also replaced the dash clock with a 2 line lcd. The
tachometer and LCD are run with an Arduino.
|Top Speed||105 MPH (168 KPH)|
105mph on flat ground verified by GPS
|Acceleration||0-60 is 14 seconds using only 2nd gear|
It will easily break the front wheels loose in 1st gear.
|Range||100 Miles (160 Kilometers)|
The farthest I've taken it is 70 miles, but based on the battery
capacity, it should do 100.
|Watt Hours/Mile||350 Wh/Mile |
Typically 40 miles = 40Ah = 320 whr/mile
Keeping a light foot I can do 40 miles with 35Ah =
|Seating Capacity||5 adults|
|Curb Weight||3,700 Pounds (1,681 Kilograms)|
actual weight without driver. Previously, I had 25 Optimas,
the car weighed in at 4010 lbs.
Installed custom rear springs to prevent sagging in the rear.
|Conversion Time||1 day per week for 9 months|
|Conversion Cost||$30k so far. |
$2k was for air conditioning.
$12k was for batteries
$2.5k was for the charger
$1k for cable, lugs, angle iron
$1.8k was for the car
$1600 for my Siemens motor
$800 for machine work
$3000 for parts to build my inverter.
|Additional Features||I'm using a Magneflux compressor for air conditioning. |
Electric power steering using a Renault Kangoo electric pump and custom hydraulic
My home built inverter is proving to be 100% reliable, 33k miles an no issues!