motor mountedcoupler done thru e-machine shopcontrolllercharger controller board  EMW
OwnerR Rivera
Owner's Other EVGiant ATX
LocationPurcellville, Virginia United States map
Web/EmailWebPage email image
Vehicle1991 Toyota MR2
I am using this car to drive 60 miles every day. And about 25 - 100miles on the weekends.
MotorHPEVS AC-50 3-Phase AC
The warp 9 armature was destroyed due to high rpm usage. Got a good deal on a hpgc ac50 controller combo. same power much more reliability.
DrivetrainRear Wheel 5 speed transmission
just recently removed the clutch. Response is better. Shifting is barely a problem. Basically use 2 and 3rd gear to 60mph
ControllerCurtis 1238-7501
550Amp 96v ( max of 126 - will use with 36 cells -115.2v )
Batteries36 CALB/Skyenergy 130AH, 115.20 Volt, Lithium Iron Phosphate
36 CALB 130AH (115V ~15KWH )
System Voltage115 Volts
ChargerElcon pfc 2500 (2.5kw) / EMW10000 (10kw - tested suc
will use EMW 10K - with 70Amp toroids - will provide 12kw quick charge 45min-1:10min full charges. Tested at 50amps.
DC/DC ConverterIota 55A
max 750watts
InstrumentationJLD404 Intelligent Amp/hr meter works incredibly well.
separate volt meter

will not longer use the 5 celllog8s to track each of the batteries, batteries got almost destroyed since the cellogs get their power from the left most 6 batts, leaving the other 2 intact. The result, unbalanced my bottom balance. the voltage went down to 90V
Top Speed100 MPH (160 KPH)
on 5th could do 100+
Accelerationhopping for 10-12 sec 0-60
Range50 Miles (80 Kilometers)
to 80% dod - 40-55 miles
to 100% dod - 50-60 miles
to 80% dod - 30-45miles
to 100% dod - 35-50miles
Watt Hours/Mile250 Wh/Mile
EV Miles
Current:6,000 Miles (9,654 Kilometers)
Seating Capacity2 adults
Curb Weight2,350 Pounds (1,068 Kilograms)
the vehicle org weight was 2640.
now in the process of eliminating unnecessary weight. hopping for 1800-2100
converting the car into a roadster with fiberglass body including doors. Custom dashboard and eliminating the trunk to shorten the car.
Tires195/50/15 Falken + Motegi DR121
will later change the rear tires to 205/60/15
Conversion Time12 month so far
Conversion Costmotor/controller $2500,cables $250, vacuum pump $388,dc-dc conv $150. $6300 batteries
backup charger $713, adapter plate $850, new tires and rims $800, new calipers and rotors $270
Additional Featuresfuture modifications:

* 36 batteries will be moved to the cabin behind seat and where the gas tank used to be. (ala chevyvolt)
* Paint car
* led light upgrade markers
* flushed headlight 25w led projection ( corvette led HLs)
* advanced instrumentation.
* weight shedding
* aerodynamic fixes
Bottom balanced batteries within 30mv of each other @ 2.74v first charge rendered about 3.38v/cell with a charging voltage of 3.48v (under charging). Car is legal now. Battery #14 overheats...getting a replacement.

after a 1000 miles, one trip consumed about 121ah (96%)... all batteries still 3.22v (within a few milivots from each other )

one battery went bad terminal overheated and melted. Now I added 2 more battery using pfc2500 set to 35 batteries and 3.5v, with 36 batteries they are undercharged to about 3.4 don't loose much..but gain on reliability

Other 4 batteries have moderate to severe sag problems. Looking to get them replaced by the manufacturer. They still work some sag to 2.5v and one sags to 1.7v @ 400amp

On Jan 10 DC motor was destroyed due rpm over speed. In view of issues that DC motor presents: carbon build up, brushes,stall problems, etc. and also the evidence of other EV builders and their experience with DC motors, I got to the conclusion that for reliable transportation purposes is better to use AC induction motors due to their reliability and Regen capabilities.

An AC50 setup was bought for a deal $2500 brand new. this included the 1238-7501 controller (550Amps)

An extensive weight loss has been implemented in order to make the most of the AC50.

4 bad batteries replaced by calb.

code by jerry