Van - front viewVan - back view60HP Motor View 160HP Motor View 260HP Motor Name PlateBatteries and test speed controller
OwnerKrystian Bialous
Owner's Other EV2006 Longzai
LocationWinnipeg, Manitoba Canada map
Email email image
Vehicle1994 Ford Aerostar AWD Eddie Bauer Edition
Currently being converted to FULL Electric
Motor Oswald Synchronous Permanent Magnet 3-Phase AC
Model: MF16.3-6WR
60 HP
640 Nm Torque nom. (472 ft-lbs)
850 Nm Torque max. (627 ft-lbs)
5500 RPM max.
350 Vac 3-phase
Water Cooled
Weight: 244 Kg (537 lbs)

Link:
WebPage
DrivetrainFinal setup:
Direct Drive - ie. Motor connected directly to the AWD transfer case. (NO TRANSMISSION)

Test setup:
5 HP 3 phase AC Black Max Marathon electric motor connected to the 5 speed manual transmission using original clutch.
Original specs:
5 HP 230/460 Vac 7A @ 60Hz 1765 RPM

Motor re-wired as an emotor (now outputs):
10 HP 460 Vac 14A @ 120Hz 3530 RPM (5500 RPM max)
Controller Custom Built
Final setup:
1200 Volt Max
600 Amp Max
Water Cooled
IGBT power stage using:
PRX IGBT CM600HA-24H MODULES

Test Setup:
Modified Allan Bradley 1336-B030
30HP at 460Vac
Modified to run directly from batteries.
Batteries44 Power Sonic PS-12180, 12.00 Volt, Lead-Acid, AGM
Total pack weight: 554.4 lbs
Vmax = 634 Vdc (fully charged)
Vnom = 528 Vdc
System Voltage528 Volts
Charger Custom Built
120Vac or 240Vac Input
480Vac Out: gets rectified, filtered and boosted to recharge the whole pack.
Based on Square D 2KVA 2S1F Transformer.

Weight: 50 lbs
HeaterCustom Built Peltier Junction unit. Supplies Heat in winter and AC in the summer with the flick of a single switch.
DC/DC Converter Custom Built
Modified PC ATX power supply. 408 Watt max. (12 Volts @ 34 Amp.)
InstrumentationOriginal Digital Dashboard plus Volt and Amp meters.
Top Speed40 MPH (64 KPH)
Still in process of being assembled and finished. Currently jurry rigged with a 5 HP Motor running thru a 5 speed manual transmission running on an Allan Bradley 1336-B030 (30 HP) speed controller. Motor gets quite warm.... It's pushing a lot of weight.
AccelerationFaster then a snail, slower then a rabbit! LOL... 5 HP 15 ft-lbs torque motor moving just over 4000 lbs of dead weight speaks for itself. The fact that it moves at all is good.
Tires235/75R15 @ 48 PSI
Conversion Time3 years to find most of the parts and decide on how to do it.
Build time is still being added up.... :-)
Conversion CostRough costs so far (I'll update with exact figures later):
$1100 - batteries
$ 520 - motor (used)
$ 350 - Used Van
$ 205 - charger (so far)
$ 80 - DC-DC Converter
Additional Features* 12 Volt electric power steering pump.
* 12 Volt diaphram vacuum pump (18 in-Hg max) for the power brakes and heating/cooling controls.
* 12 Volt 165 Watt electric mini fridge powered by dedicated dc-dc converter.
* rear Munroe Air Shocks used for ride hight adjustment


* Future upgrades:
- 400 Watt (minimum) roof mounted custom built solar panel, with a custom MPPT connected to recharge the main battery pack.
- hidden 1000 Watt vertical axis wind turbine (lowered and raised electrically with switch on dash)
- Replace all light bulbs with LED lights. Replace front 55 Watt Headlight bulbs with 35 Watt HID lights.
The van originally had an automatic transmission. It was replaced with a manual 5 speed tranny from a 1992 Ford Ranger 4x4 Truck. Direct bolt in conversion. No modifications were required to fit the manual transmission.

This is a Project that is still in the process of being finished. Currently I'm trying to make the adapters to connect the electric motor directly to the Transfer Case.


Original Specs:

Curb Weight: 3481 lbs.
Length: 174.9 in.
Width: 71.7 in.
Height: 72.2 in.

Wheel Base: 118.9 in.
Maximum Cargo Capacity: 140 cu. ft.
Maximum Seating: 7

Base Engine: 4 liter V6
Horsepower: 155 hp @ 4000 rpm
Torque: 230 ft-lbs. @ 2400 rpm
Drive Type: AWD

Mileage on Automatic transmission:
14 mpg / 18 mpg (City/Highway)

Mileage on Manual transmission:
16 mpg / 20 mpg (City/Highway)

code by jerry