Hydraulic pump
OwnerBalázs
LocationBudapest, Central Hungary Hungary map
Vehicle1993 Citroen Xantia
ICE was 1.8 l petrol engine, 75kW.
Hidropneumatic suspension I. generation.
Servo brake and servo steering system.
MotorKostov DC 6,3/7,5/14 11 Series Wound DC
11" Balkancar forklift motor from 1970.
93 kg 6.3 kW at 80V 1400 RPM. The
4 poles in series have been connected
in parallel (2-2)for higher speed. The
brushes are also advanced. The original
transmission is assembled by home made
adapter plate. The system is clutch-
less. The original clutch plate is used
for coupling.
DrivetrainManual 5 gears
ControllerOpen ReVolt 500A
The high current part is almost the same
as
Open Revolt, but instead of micro
controller
the old TL494 PWM controller works with
current mode. Hall sensor is used for
throttle.
Batteries45 Tornado, 3.20 Volt, Lithium Iron Phosphate
100Ah cells form Tornado Science Groups
Limited (tnd-battery.com)
System Voltage144 Volts
Charger
Home made analog distributed
BMS. Similar to the MiniBMS.
DC/DC Converter
Not decided. Original 12V lead acid is
still used.
Top Speed80 MPH (128 KPH)
expected
Range30 Miles (48 Kilometers)
expected
Seating Capacity5 adults
Curb Weight0
The original weight was 1250 kg. I hope
the original weight will be kept.
Conversion Timestarted: 18.04.2012
Additional FeaturesThe hydraulic pump for suspension,servo brake, and the
servo steering originally were driven by belt from ICE. Now
an auxiliary permanent magnet DC motor is used. Brushed DC
motor (from treadmill). It is 180V 3LE at 4000 RPM. The belt
gear is 11:6 having enough torque for 175 Bar
pressure(tested an worked from 24V).

02.10.2012 The project is running. The series wound DC
attached to the transmission gear by home made adapter
plate and mounted into the car. The hydraulic pump assembled
with auxiliary DC motor.

25.04.2013 The 40PCS of batteries arrived. The build of BMS
and Charger is in progress.
25.05.2013 The home made hall sensor based throttle works
fine.
First trip with 10 pcs battery cells.

30.08.2013 The process is slow, but there is progress. The
1/3 of the cells are in the car. I have done some short
trips
(road tests). I have discharged and charged cells ones, so
the first cycle has been done :). The max amperage is still
limited to 200A during discharge.

The controller (144V/500A).
The BMS I designed works perfectly. It alarms when the
voltage is under 2.5V and above 3.85V. The balancing starts
above 3.65V.
19.10.2013 Road test with 30 cells (96V) at 200A limit. Top
speed is much higher than at 48V.
27.12.2013 First road test with 45 cells. The continuous
300A was not possible due to the voltage sag and BMS
alarmed. The acceleration was good at 300A. Max speed was
60kmh.

code by jerry