Engine BayMain Battery Box
OwnerChristopher Walkden
LocationSelbourne, Tasmania Australia map
Email email image
Vehicle1992 Subaru Brumby
4WD Subaru Brumby utility. The Brumby was sold as a "Brat" in some countries.
MotorKostov 17R Series Wound DC
Has an over temperature switch, which I have wired into a handy warning light in the dash.
DrivetrainOriginal 4WD gearbox with clutch
ControllerKelly KDH14800D
The first one blew up, but Kelly quickly replaced it under warranty.
Controller is mounted vertically on a 6mm thick piece of aluminium. There are spacers under the aluminium so that air can flow through underneath. Also two 12V fans are mounted on top of the controller.
Batteries12 Century Battery Company C12-140DA, 12.00 Volt, Lead-Acid, AGM
140Ah @ C20
I used Lee Hart's Zener regulators to help keep the batteries balanced.
System Voltage144 Volts
Charger Chennic JCWP14408
Secondhand charger was cheap if slightly undersized. Takes about 9 hours to charge after a 36km trip.
The charger does not always turn off automatically like it is supposed to. This may be because of the zener regulators on the batteries. I built a circuit that turns it off if the lamps glow brightly for a few minutes.
Heater12V Hairdryer
DC/DC ConverterIota DLS-55
InstrumentationZeva Fuel Gauge Driver + shows "state of charge" using the fuel gauge. It also shows instantaneous current draw using an aftermarket tachometer that I bought for the purpose.
I also use the exsisting engine temperature gauge. I have a switch so that I can see the temperature of either the motor or the controller. I have glued thermistors onto the motor and controller.
Top Speed71 MPH (114 KPH)
This speed is readily attained. Might go faster under ideal conditions.
AccelerationOK, considering how heavy it is. To get better acceleration, change up a gear.
Range31 Miles (49 Kilometers)
50km trip along a road with some hills, some T junctions & many corners.
Can go 60km (or more) if speed is limited to 60km/h.
Watt Hours/Mile384 Wh/Mile
This was from a trip of 36km, not many hills but lots of corners.
EV Miles
Start:154,550 Miles (248,670 Kilometers)
Current:156,380 Miles (251,615 Kilometers)
Total:1,830 Miles (2,944 Kilometers)
 
    As of 3/7/2013
Seating Capacity2 adults
Curb Weight3,218 Pounds (1,462 Kilograms)
Since it is a utility I could add extra weight without going over the manufacturer's limit. It is now exactly on the limit.
TiresLow Rolling Resistance
Conversion Time18 months
Conversion Cost$12,000 Aus Dollars
Additional FeaturesBatteries are heated when plugged into the mains socket.
Demisting is required by Australian regulations, this is provided by a 12V hairdryer mounted pointing at the windscreen.
Kostov motor seems well matched to the Kelly controller. The motor gets to about 60°C under heavy load but the controller only gets to about 40°C. The highest I've seen current draw is just over 500A (at battery).

code by jerry