It's out!Plywood adapterSmall BMU networkMiddle battery boxesFitting cells
OwnerMike and Dave
LocationBrisbane, Queensland Australia map
Email email image
Vehicle1990 Mazda MX-5
Sporty convertible with low centre of gravity and excellent road holding; original ICE was 1.6 L
MotorAsea Brown Boveri 3GAA 131 008E 3-Phase AC
22 kW, 2 pole, long 132 frame, Aluminium frame
DrivetrainStandard 5-speed manual gearbox and clutch; considering 3.636:1 diff (in place of stock 4.3:1).
Controller Tritium Wavesculptor200
165 kVA 450 V
Batteries228 Skyenergy SE40AHA, 730.00 Volt, Lithium-Ion
Sky Energy SE40AHA Lithium Iron Phosphate x 212 via bulk buy from EV Components. Added another 16 from EVworks
System Voltage730 Volts
ChargerElcon TCCH-312-06
With CAN bus option.
May attempt to use the AC drive to charge the pack, if not too expensive
Heater12 V 180 W dash mount demister
DC/DC Converter
Were planning to use existing alternator, but 2x 240 VAC 13.8 V power supplies in parallel across each half of the pack seems more likely now
Top Speed82 MPH (131 KPH)
Assuming 3.636:1 diff
AccelerationUnknown; aiming for better than original ICE
Range75 Miles (120 Kilometers)
Rough guess
Watt Hours/MileUnknown
EV Miles
Start:148,943 Miles (239,649 Kilometers)
Current:148,943 Miles (239,649 Kilometers)
Total:0 Miles (0 Kilometers)
Seating Capacity2 adults
Curb Weight2,163 Pounds (983 Kilograms)
Before conversion. Engine and gearbox combined are 170 kg.
TiresStock
Conversion TimeStarted in February 2009.
Conversion CostBatteries AUD 13K (212) + AUD1K (16)
Controller AUD 7K inc GST
Motor AUD 2600
Additional FeaturesReplaced manual steering with power steering
Planning to keep existing air conditioning
Attempting to produce a sporty conversion with better performance than the original. We plan to do more MX-5s to amortise the learning costs over several conversions.

2009/Apr/1: the engine is out. Still considering two lithium battery options: 40AH Thunder Sky, or 30AH China Power (high discharge versions).

2009/June/7: Batteries ordered weeks ago; controller arrived; motor almost ordered (just waiting for final options). Motor will take 5 weeks to manufacture and 9 weeks (!) to ship.

2009/Oct/13: Batteries arrived months ago; started battery racks. BMS PCB design completed and prototype arrived. Motor ordered and now due late December; we may have to go with a smaller off-the-shelf ABB motor for this first conversion.

2009/Dec: Having completed an analogue BMS design, we're now considering a redesign using a microcontroller per cell. Three battery cages are welded (no cells installed yet).

2010/May: Decided to switch from industrial controller to Tritium Wavesculptor200. Motor has arrived, and we have a plywood "adapter plate" for measurements.
Completed the digital BMS design; testing prototypes. Almost complete on 5 battery boxes. Set goal of being self-powered (not complete) by 22nd June 2010.

See also our AEVA Member's Machines page: WebPage

code by jerry