GN250 ConvertionGN250 Convertion 1aFrame 1Frame 2Throttle linkageNew Rear SprocketBattery Shelf arrangement1st Car Park Test
OwnerPhilip Hortin
LocationPerth, Western Australia Australia map
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Vehicle1995 Suzuki GN 250
Motor 1.5Kw 4 pole AC induction motor 3-Phase AC
Standard industrial motor
Drivetrainchain drive
ControllerDanfoss VLT2800

Able to supply 160% torque cont (2.2Kw) and 180% torque for 2 seconds
includes regenerative braking
DC bus sharing, (battery pack connected into DC bus)
Batteries28 Henda HT12V7.2, 12.00 Volt, Lead-Acid, Gel
28 x 7.2 Ah Sealed Lead Acid making 336 volts @ 2.2Kw capacity, They are broken down to 48 volt packs by using 6 relays in line when the controller is powered down.
System Voltage336 Volts
Custom made isolating transformer (5x 50V 50va & 1x 36V 50va wired primaries in parallel and secondaries in series) with 240VAC input and output stepped up to 287VAC for fast charge and 261VAC for float charge plugged into the Danfoss AC power input. Charge mode controlled by Picaxe micro-controller
HeaterLooking forward to not having one (petrol engine and radiator) generating vast amounts of heat under my seat and legs while sitting at the lights in summer (30 - 45 deg c)
DC/DC ConverterPowertran STD-1204(M8938)
Two off the shelf switch-mode adapters, input range 90-264VAC, Output 12VDC at 4 Amps. One to run the 12V relay control/instrumentation, and one to run the motorcycle lighting.
Both powered from the 336VDC pack
InstrumentationThe planned instrumentation is an 8" TFT LCD panel with touch screen, controlled by a Parralax propeller chip. Inputs will include - speed, pack voltage, pack current (discharge/ regenerative braking charge) estimated pack capacity and range @ current power draw.
Top Speed67 MPH (107 KPH)
AccelerationUnknown- The electric drive train ratios equate to the torque value obtained in 2nd gear at maximum petrol engine output (7500 rpm)
Seating Capacity1 adult
Conversion TimeSo far 3 months before and after work hours. Average 7 hours a week.
Conversion CostBattery pack, controller, and relays -$600 Australian
4 pole 3 phase motor - $220 Australian
76 tooth industrial sprocket - $120 Australian

First car park trials with the motor connected in delta revealed that the expected torque was not achieved due to the conntroller reaching its internal current limit, and top speed could not be established due to the limited space available. (but was promising)

With the motor connected in star the torque was improved to a normal vehicle acceleration on level ground. The top speed was limited to 40km/hr because the motor voltage was only able to reach 270 volts AC insted of the full 440 volts AC. This is due to the DC pack voltage of 350 volts and the motor connected in star.

The future plans include a 3.7kw Danfoss controller so the 1.5kw motor can be pushed hard during the initial acceleration (220% rated torque). The other upgrade is a new larger rear sprocket. The current sprocket is the standard 41 tooth but this will be increased to 76 teeth after modifing an industrial sprocket sourced from Renold Australia.

The 76 tooth industrial sprocket has had the hub turned off and the centre hole enlarged to suit the orriginal GN250 hub and mounting bolts. The thickness was also reduced form 9mm to 6mm to suit the standard 520 DID chain.

code by jerry