North Bay Electric Auto Association



North Bay Electric Auto Association



Open Source Electric Vehicle Program

Economy Electric Vehicle Conversion Procedure

Chris Jones 9/2/2009

To be filled in as sections are written

Table of Contents

1. ICE Component Removal Preparation

1. Weigh vehicle

2. Measure ride height

3. Make transaxle locating fixture

2. ICE Component Removal

1. Radiator

2. Starter Battery

3. Exhaust System

4. Engine

5. Fuel system

3. EV Component Installation

1. Motor

2. Front Battery Box

3. Rear Battery Box

4. AC Inlet Assembly

5. Conduit Assembly

6. Accessory Battery

7. Radiator Box completed

8. Wiring Loom

9. Console

4. Verification Test Procedure started

5. Appendix

1. EV Component Analysis

2. Donor Car Analysis

3. EV Component Fabrication Procedures

i. Motor adapter

ii. Motor mount

iii. Front battery box

iv. Rear battery box

v. AC inlet assembly

vi. Conduit assembly

vii. Accessory battery mount

viii. Radiator box and mount

ix. Wiring loom

x. Console

3. EV Component Installation

Note: use lock washers on all fasteners so they remain tight in an automotive vibration environment.

3.7 Radiator Box

3.7.1 Install radiator box mount on radiator box, 4 places.

[pic]

2. Place radiator box in car. Insert 4 bolts to hold radiator box mount to car. Use lock washers and nuts to secure mount to car.

3. Verify circuit breaker is switched to off position, located on the right side of the radiator box.

[pic]

4. Make large cable connections to 4 terminals on right side of radiator box:

[pic]

1. Connect motor cables from motor to M+ and M-, the two lower terminals located on the right side of the radiator box.

[pic]

Note: polarity does not matter, since this is a series wound configuration.

2. Connect negative battery cable from the most negative battery in the front battery pack to the B- terminal, the terminal just below the top terminal on the right side of the radiator box.

[pic]

3. Connect positive battery cable from the most positive battery in the front battery pack to the B+ terminal, the uppermost terminal on the right side of the radiator box. Note: take precautions to avoid electric shock, which are not explained here.

[pic]

5. Make small cable connections to 7 terminals on left side of radiator box:

[pic]

1. Connect ground cables from the chassis and the negative terminal of the accessory battery to the GND terminal, the top terminal on the left side of the radiator box.

[pic]

2. Connect 12 volt accessory cables from the original ICE loom and the positive terminal of the accessory battery to the 12V_ACC terminal, the terminal right below the top terminal on the left side of the radiator box.

[pic]

Original 12 volt accessory ICE loom includes 5 cables coming from the main bulkhead connector on the firewall in front of the driver:

4 pink

6 black

35 black-red

36 pink

40 red

[pic]

3. Connect 10A fused ignition key switch wire from original ignition switch ICE loom, the dark blue wire connected to pin 38 of the main firewall bulkhead connector in front of the driver to the IGN_F terminal, the upper left terminal on the group of 8 terminals on the lower left side of the radiator box:

[pic]

[pic]

4. Connect POT_COM and POT_NO terminals, the upper right two terminals on the group of 8 terminals on the lower left side of the radiator box, to the outer two contacts of the microswitch on the potbox, common and normally open terminals.

[pic]

Note: polarity does not matter.

5. Connect POT_R1 and POT_R2 terminals, the lower right two terminals on the group of 8 terminals on the lower left side of the radiator box, to the twisted pair variable resistor wire on the potbox.

[pic]

Note: polarity does not matter.

6. Install L5-15 locking AC plug in to AC inlet on lower left corner of rear of radiator plate.

[pic]

4. Verification Test Procedure

Note: these batteries can deliver over 20 kW continuous and far more for short durations, which can be very dangerous. Do not attempt this procedure without proper high voltage and automotive training.

1. Static

1. Jack the front of the car up and put it on jack stands.

2. Put transmission in neutral.

3. Verify traction battery pack voltage across B+ and B- on the right side of the radiator box is between 80V if fully discharged and 117V if fully charged and right off the charger. Typical rest voltage after full charge is 105V.

4. Verify the voltage across 12V_ACC and GND on the left side of the radiator box is between 10.5V if fully discharged and 13.5V if fully charged and right off the DCDC converter. Typical rest voltage after full charge is 12.8V.

5. Turn on circuit breaker on right side of radiator box. Make sure it stays on and no heat or smoke comes out of any of the EV components in the vehicle. Reverify the ~105V across B+ and B- on the radiator box did not change.

6. Turn the ignition key to the on position. You should hear the main contactor click on and off. Verify the voltage across 12V_ACC and GND has risen to 13.5V, indicating that the DCDC converter has turned on.

7. Lightly press down on the accelerator pedal. Note: do not press too far, which can over-rev the motor. You should hear the main contactor click on when the pedal is depressed, then the motor should start to turn but not the wheels. Then release the accelerator pedal. The main contactor should click off and the motor should stop turning after several seconds.

8. Shift the transmission in to 1st gear and repeat the test. Make sure the wheels spin forward.

9. Repeat the test for 2nd, 3rd, 4th and reverse. Make sure the wheels spin in the proper direction.

10. Turn the key off. Verify the voltage across 12V_ACC and GND goes back down to 12.8V.

11. Plug the charger in to a 120V AC outlet with a 15 amp extension cord from the inlet located behind the original gas filler door. You should hear the charger beep and the charger fans go on. Verify the voltage across B+ and B- has risen approximately 1-2 volts.

12. Unplug the extension cord. The charger and its fans will go off.

13. Remove the jackstands from the front of the vehicle.

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