OwnerJames Killick
LocationBasildon, England United Kingdom map
Web/EmailWebPage email image
Vehicle1996 Ford Probe
The Probatron was in good working order before I started the conversion. It was always intended to be the donor car since I bought it about 3 years ago. I love the way the Probe feels to drive and the way it looks. Once I have the conversion to electric done, I will get a sweet paint job. Update (7th Sept 2010) On the road legally since 9th March 2010. Recently changed batteries for new ones. Now that paint job......!
MotorAdvanced DC FB4001 Series Wound DC
The two wires hanging out of the motor are an overtemperature switch. There is a 5/8 UNC blind hole in the side that can be used to mount the old engine coolant temperature sensor, so this can connect to the instruments like before and you can monitor the motor temperature using the original temperature gauge. Update (7th Sept 2010) gauge didn't work. regular checks prove nothiung gets too hot, even in the height of summer. I can monitor the motor controller temperature through the programmer unit test functions.
DrivetrainProbe 5 speed gearbox with clutch. Taperlock hub and adapter to the flywheel.
ControllerZapi H3D
DC 800A controller with regen braking. Using the Zapi programmer, there are lots of settings that can be adjusted to the way you want to drive.
Batteries10 Hawker Powersafe 12V105F, 12.00 Volt, Lead-Acid, AGM
I got my batteries from a recycler, very cheap and excellent condition. The manufacturer have recommended their traction batteries, but these are meant for a telecomms back up supply. They say they are good for about 6 months with heavy loading. I expect they will last longer. I have my eye on some carbon fibre lead acid dry cells from elecsol, 150AH 12v. Reasonable price, but I have other priorities at the moment. Update (7th Sept 2010) got new batteries now, Lucas SLC150-12 AGM lead acid. They are performing well, but some way off to afford Lithium yet.
System Voltage120 Volts
ChargerZivan NG3 120v
HeaterCeramic heater that I got a friend in USA to buy from Walmart, mounted inside the original heater matrix. It works well at 120v dc.
DC/DC ConverterIota DLS 55
55A DC-DC converter. With the 120v pack connected I got 13.5 volts at the output. I now use the quick charge link as this maintains the system much better and puts out about 14.2v (about the same as an alternator)
InstrumentationI am planning to make a circuit that will convert the current shunt voltage to a signal suitable to display A x 100 on the old rev counter (tacho) and proportional voltages to make use of the old fuel gauge as a state of charge indicator. I also plan to make a matrix display for voltage on 10 batteries as 10 bargraphs (in dot mode). I can make more if you are interested! Update (7th Sept 2010) I have the state of charge bargraph complete and working for some time now. I am building the Ax100 bargraph with ultra-bright blue LEDs behind the mask of the numbers 0 to 8 on the tacho/rev counter gauge. I have the LEDs mounted and I am putting together the sensor circuit using a hall effect current sensor around one of the main power cables, much better than using a shunt. This will provide the signal for a bar-graph display driver chip for the LEDs to light up. The battery monitor system I have designed will now use an LCD matrix display to show the instantaneous voltage level for all of the 10 batteries at once, also to show the combined maesured voltage and the instant current as numbers and a Probatron logo that I designed.
Top Speed95 MPH (152 KPH)
Not running yet, but I doubt if I will drive it too fast as it will flatten the batteries quicker. Update (7th Sept 2010) I have had it up to 95MPH, but I normally drive in 3rd gear only and this tops out at about 65MPH and this suits me most of the time.
AccelerationThis is where I am looking forward to the grin factor. The 800A controller through a 5 speed gearbox should get some wet knickers. Update - it does....
Range30 Miles (48 Kilometers)
I am hoping for at least 50 miles from a charge. I have got up to 18 miles so far, but I have just switched on the regen for throttle lift-off only (14th March 2010). I need to integrate a clutch switch and brake switch into the controls to get the full benefit of regen and keep the flexibility of having a gearbox. Update (7th Sept 2010) 50 miles was optimistic for lead-acid in this fairly heavy car, but 30 is comfortable and I have done this several times since fitting new batteries. These journeys have all been stop-strat and some with lights on and no charge overnight. There is still more to be had, but I need to get a good run somewhere that is safe to return without discharging too much. I don't want to damage my batteries.
EV Miles
Start:200,465 Miles (322,548 Kilometers)
 
    As of 9/7/2010
Seating Capacity2+2 adults
Conversion Time10 months.
Additional Features7th Sept 2010 update:
I have added a sport/economy switch some time ago and this is ued to control if I have lots of regen braking with limited speed (economy) or a small amount of regen braking with unlimited speed (sport).

code by jerry