| Owner | J Anderson | ||||||||
|---|---|---|---|---|---|---|---|---|---|
| Location | Prince George, British Columbia Canada map | ||||||||
| | |||||||||
| Vehicle | 1990 Mazda Miata Red Hardtop and Black Softtop | ||||||||
| Motor | Siemens PV-5133 3-Phase AC Liquid cooled motor originally manufactured for Ford Ranger pickups. Motor complete with quadrature encoder and winding thermocouple | ||||||||
| Drivetrain | Stock transmission with clutch | ||||||||
| Controller | Azure Dynamics/Solectria DMOC 645 originally aircooled now liquid cooled | ||||||||
| Batteries | 99 Thunder Sky 60AH, 3.35 Volt, Lithium Iron Phosphate 30cells in the trunk 39cells in place of gastank 30cells under the hood | ||||||||
| System Voltage | 332 Volts | ||||||||
| Charger | Elcon PFC-2500 TCCH-288-06 Charger setup for a standard 120v 15amp plug as well as a 240v 15amp plug at home. On a 240v plug the batteries charge at 7.4amp | ||||||||
| Heater | 2 x 1500 watt ceramic heaters mounted in place of the old heater core | ||||||||
| DC/DC Converter | Iota DLS-220-55 | ||||||||
| Instrumentation | Stock gauges driven by a customer programed ESP32 controller which will interface via bluetooth low energy with an GEVCU 6 from www.evtv.me | ||||||||
| Acceleration | Acceleration is better than stock and the drive is currently limited by software to 200ftlbs to save the transmission and rear differential. | ||||||||
| Range | 70 Miles (112 Kilometers) The design goal is a range of at least 70km on 80% of the battery capacity at 70km/hr. | ||||||||
| Watt Hours/Mile | 275 Wh/Mile 260 Whr/mile driving around town | ||||||||
| EV Miles |
| ||||||||
| Seating Capacity | 2 adults | ||||||||
| Curb Weight | 2,620 Pounds (1,190 Kilograms) 52% rear and 48% front, which is quite close to the original 50/50 | ||||||||
| Tires | stock | ||||||||
| Conversion Time | way way to long.... | ||||||||
| Additional Features | Power Steering thanks to an electric power steering pump from a 2007 Volvo V70. Flying Miata replacement coilover shocks (https://www.flyinmiata.com/NA/na-fm-v-maxx-classic-coil-overs.html). Miata NA to NB top hat conversion. JLD404 amp hour meter for tracking power consumption and battery capacity. | ||||||||
| After much research, time, effort, setupbacks and wins the project is now cruising the streets. July 28, 2022: Resolved some software limits that was limiting the duration of full throttle as the converter thought the motor would be overheating July 8, 2022: Setup Regen and one peddle operation. It feels great to be regenerating some charge when slowing down for traffic lights. June 19, 2022: The car was a complete hit at the Fathers Day show. People were gathered around the car all day. June 17, 2022: The car is on the road and will be shown at the Father's Day car show Feb 13, 2011: The contactor box is under construction and the all the parts are on hand. Mar 02, 2011: The copper bus is finished and the contactors are being properly controlled by the VFD to allow the precharge to occur. A 12 volt signal from the cars 'start' position on the ignition switch will start the whole process using a optically isolated TRIAC Apr 10, 2011: The plan was to order batteries in June. The supplier provided an update that the next order had been moved move to the middle of April. The rush is on to finalize the numbers and configuration........ Apr 13, 2011: The battery order is placed. 106 60AH Thundersky batteries should leave on a boat from China around April 26th :) Apr 17, 2011: The machinist has finished making the coupler to go between the motor shaft and the clutch. Nice job and the 60611T6 Aluminum was quit light even though it is almost 3-1/2"OD. The adapter plate to mount the motor to the transmission was printed on paper and transferred to plywood for a test fit. Everything fits perfectly. There is room for the motor mounts and batteries. I would post some pictures but there is a problem with EV Album not accepting uploads. Next on the list is to mount the electric power steering pump and get a custom hose made. Apr 26, 2011: Custom power steering hose was fabricated. Unfortunately there appears to be a problem with the electric power steering pump...the smoke has been let out:( May 24, 2011: Pickup up the batteries. The manufacturer kindly racked and strapped the batteries as per the layout required for the car. All the cell had a measured voltage of 3.29 or 3.28 volts. May 29, 2011: The fabrication of the motor mounts is complete. There is no longer a need to support the motor and transmission combination with a jack or overhead rigging. June 17, 2011: Finally spent a bit of time taking apart the volvo power steering pump and discovered that the wrecker sold me a pump that was full of water. The motor had rusted to the point that it would not turn at all. That is why the electronics heated up and the smoke was released. I wonder if I can convince the wrecker to send me a replacement unit? December 15, 2011: Back at it after a much to long break. Fabrication of the Aluminium and ABS battery boxes is underway. The box for the trunk will hold 30 cells. Most of the box is where the muffler was previously located. The trunk space will be almost the same as it was before. The next box to fabricated will be located where the gas tank was removed. It will house 39 cells. The remaining 37 cells will be located under the hood in the engine compartment. March 3, 2012: The battery box that replaces the gas tank is nearly complete. The trunk box just needs to have the seams solvent glued. Working with Aluminium has been a bit of a learning process. At first I was using die grinder and rotatory file for shaping, but now the work is much faster as I got my hands on some 4" grinder discs made for Aluminium. The supplier for shielded orange cable has been found and the order should be finalized in the next week or two. April 8, 2013: It has been quite sometime since the last update. The Volvo electric pump steering pump is installed and working perfectly. The Volvo electric vacuum pump for the power brakes works well, but has not been installed yet. The vacuum pump will be start and stop according to a pair of adjustable vacuum contact switches. The battery boxes for the front of the car are 95% complete. Only 30 batteries are mounted in the front of the car as compared to the original plan of 37. So perhaps a bit less range, but on the up side there will be some spare batteries and perhaps even a swap out of the 12V aux battery from Lead to LiFePO4. The DC/DC convertor is mounted and wired up. A 250volt 30Amp flange mounted twist lock charge inlet port has been installed where the liquefied dinosaur farts were previously added. The instrument gauge has been characterized and can be driven by the Arduino control module. RPM, fuel, temperature will read and respond the same as before. The oil pressure gauge will be changed to display actual battery current instead of it�s original OEM function. The work and fun continues. April 29, 2013: The twist lock power inlet is hooked up and giving the car some life. Plug it in, turn the key to �ON�, then �START� and everything powers up. The DC/DC convertor tops up the 12V battery and powers all the accessories. The throttle linkage is hooked up to the hall effect throttle pot. The pot was modified to include a blue LED and a 5 volt regulator. The output of the pot is wired to the Analog 2 input of the Allan Bradly VFD. The VFD is configured to accept a 0.0 to 4.75 volt input and is mapped to a 0 to 8500RPM range. April 2017: There was a sale on aircooled DMOC 645 controller. At $495 how could I resist? The DMOC would allow the efforts at a DIY controller using a VFD and a large IGBT module to be scrapped. Also purchased a GEVCU 6 in order to feed the CANBUS signals to the DMOC. May 2017: The DMOC controller is going to be a very tight fit and requires some rework of the front battery boxes. Some of the cooling fins on the DMOC will need to be trimmed for the hood to close. At first there were a lot of CAN bus errors with the new controlled. The source was tracked down to a difference of ground potential between the car adnt eh desktop computer that was plugged into the debug port�. After correctly that problem the motor ran like a charm. July 2017: The fabrication of the aluminum transmission plate was completed using a local CNC shop. The motor and transmission were removed and the temporary plywood trans plate was replaced with the shiny new 1� thick 6061-T6 unit. What a thing of beauty. Installed a new clutch, input bearing, throw-out bearing and driveshaft seal before the motor/trans unit was reinstalled in the car. Drained and replaced the trans fluid. Making some progress seems to be just the boast in motivation that was needed! | |||||||||
1990 Mazda Miata
Last Updated 08-06-2022
Copyright © 1997-2024 by Mike Chancey