Engine CompartmentCALBs in back seat
OwnerGreg Straeffer
LocationChelmsford, Massachusetts United States map
Web/EmailWebPage email image
Vehicle1998 Saturn SC2
Purchased in Feb 2009 with a blown engine
(crankshaft bearings completely shot)
MotorAzure Dynamics/Solectria AC-24LS 3-Phase AC
Retained the clutch.
Drivetrain5-speed, FWD
ControllerAzure Dynamics/Solectria DMOC-445
Batteries50 CALB/Skyenergy CA100Ah (grey cells), 3.30 Volt, Lithium Iron Phosphate
Batteries placed in boxes originally
designed for T-1275s, in the back seat area
(seats removed).
System Voltage165 Volts
ChargerZivan NG-3
On-board system, 220VAC input. Custom charger
control circuit (home-grown).
HeaterElectric water heater, MES-DEA RM-4. Water
temperature displayed via dash coolant temp
gauge.
DC/DC ConverterElcon
30 amp capacity (not enough!). Looking into
building a Vicor-based converter.
InstrumentationAnalog traction pack voltmeter, traction
pack ammeter, accessory battery voltmeter, ZEVA
Fuel Gauge Driver.
Top Speed70 MPH (112 KPH)
Some pedal left. Takes a while to get there,
though.
AccelerationThe CALBs provide normal acceleration for
surface roads. The AC24LS motor is undersized
for highway driving.
Range70 Miles (112 Kilometers)
Surface road driving.
Watt Hours/Mile250 Wh/Mile
Based on average of summer and winter commuting.
EV Miles
Start:139,105 Miles (223,819 Kilometers)
Current:153,500 Miles (246,981 Kilometers)
Total:14,395 Miles (23,161 Kilometers)
Seating Capacity2 in front. Rear seats removed.
Curb Weight2,500 Pounds (1,136 Kilograms)
Estimate. Original car 2300 lbs.
TiresGoodyear Assurance Fuel Max (low rolling
resistance)
Conversion Time18 months of weeknights and weekends for
original conversion. Additional 200-300
hours to install CALBs, which included a lot
of fixing small issues in original
conversion.
Conversion Cost$500 for donor, ~$15k for original
conversion. Additional $7k for the CALB
upgrade.
Additional FeaturesVW vacuum pump for power brakes. Insulated battery box in back seat area with a homemade battery heating system (Kat's battery pad
heaters controlled by el cheapo temperature controllers).
The original conversion was woefully under-powered. AC-24LS
motor, DMOC-445, 156v PbA, and 3200 lbs is not a good combination.
The CALB upgrade shed 700 lbs from the vehicle weight. That,
coupled with the much smaller voltage sag, has made it into a
regular car. Not a hot-rod, but it can get out of its own way
now.

code by jerry