DC Generator for electric vehicleBattery pack, 38 cells TS LFP160AHABattery protection circuitActual hood since 2011
OwnerAlain St-Yves
LocationSalaberry-de-Valleyfield, Quebec Canada map
Vehicle1997 Chevrolet Cavalier
Originally converted in 1999 by Richard Lane, Ottawa, Canada. I bought the car in 2004 and installed an ICE generator to assist the battery while driving highway or long distance. In 2011, while upgrading with famous lithium battery, generator has been removed and is pulled on a small trailer only if required.
MotorAdvanced DC FB1-4001A Series Wound DC
DrivetrainManual transmission installed, no clutch pedal
ControllerKelly KDH 14600D
A separate dc/dc converter for the 12 vdc control power input is installed. This is to avoid problem. This controler doesn't have free wheel diode and the unit can burn if 12 vdc input is lost while motor is running.
Batteries38 Thunder Sky TS LFP160AHA, 3.20 Volt, Lithium Iron Phosphate
To protect the battery from over/under voltage, EV Power BMS modules with MCU-EV2 master unit are used.
BMS modules also balance battery cells at end of charge.
Battery and BMS are perfect after a year.
System Voltage120 Volts
ChargerZivan K2
About end of charge control, a special circuit built by my son trough an industrial electronic course project is used to shutdown the charger at end of charge. The Zivan has an end of charge voltage curve but it is our "school made"circuit that shut down the Zivan at a precise adjustable voltage and adjustable time delay. If any problem, the MCU-EV2 unit will disable any incoming charge if one of the cells reach 4.2 volts.
HeaterCeramic heater, 2 selections
DC/DC ConverterGo Power GPC-45
45 amp., 144-192 volts used with a small 12 ah AGM battery.
InstrumentationE-Meter, battery temperature, Voltmeter and Ammeter, Tachometer
Top Speed90 MPH (144 KPH)
Range60 Miles (96 Kilometers)
Generator assist on a trailer is possible for long distance when required.
EV Miles
Start:43,750 Miles (70,393 Kilometers)
Current:86,900 Miles (139,822 Kilometers)
Total:43,150 Miles (69,428 Kilometers)
Seating Capacity2 adults, rear seat replaced by battery box
Curb Weight3,100 Pounds (1,409 Kilograms)
Additional FeaturesFrom 2007 to 2011, while using lead acid battery, onboard 5 KW gas DC generator was used if range over 30 km was required.
In generator compartment, felt, wool and aluminum screen where used for temp. insulation and noise reduction.
Since I am now using lithium battery, generator has been removed but a small trailor generator can be pulled occasionally when required.

Battery compartment is insulated, ventilated and heated.

After 12 years with lead acid, I can say Lithium LFP battery is another world. The few times I got verry low with these battery, I can say all the 38 cells where able to give more than the specified 160 AH. After more than a century talking about better battery, we are able to see it now!

code by jerry