Removing NiCadsLi-Ion assemblyReady battery boxesHeating filmBMS control unitBMS modulesFast chargerBMS control unit
OwnerRoman Placer
LocationPrague, Prague Czech Republic map
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Vehicle2000 Peugeot 106
Original factory model with some upgrades,
especially Li-Ion batteries and fast charger.
MotorLeroy Somer SA 13 Separately Excited DC
(11kW nominal, 20kW peak), 127Nm, 72 kg
ControllerSAGEM 3YXSY3000
120 Volt 200 Amp (IGBT) 400A/600V
Batteries120 Samsung SDI 60Ah, 3.70 Volt, Lithium-Ion
Used cells originally from BMW i3 first
generation, all tested for internal resistance
and capacity, connected in 40s3p config giving
total 148V/180Ah (27kWh capacity). Installed
also 2kW battery heating system using thin
floor heating film from Aliexpress :) Works
Used BMS from, planned to use
it also to limit the charging current when
charging ends. I'm not satisfied with it at
all as it is very vulnerable probably due to
high EMC noise disturbance coming from DC
motor brushes.
System Voltage148 Volts
ChargerSagem Y3000
Original 3,2kW charger built in Sagembox +
custom built additional fastcharger from
Eltek power sources gives 9kW of DC power,
12kW in total. Next additional 9kW
enhancement planned.
HeaterWebasto Thermo top C 5kW gasoline heater.
Currently working on approx 2kW electric heating
system using 750W/120V PTC module and 2 digital
thermostats. Will be updated
DC/DC ConverterSagem Y3000
70A (1kW) original converter built in Sagembox.
Top Speed65 MPH (104 KPH)
(105kph electronicaly limited, but adjustable)
Accelerationnot yet measured
Range125 Miles (201 Kilometers)
Not yet tested, 125miles (200km) expected.
Will be updated
Watt Hours/Mile210 Wh/Mile
The consumption was in winter with battery
heating ant temps around -5°C approx 17
kWh/100km, in winter it could be around 13
EV Miles
Start:97,000 Miles (156,073 Kilometers)
Current:123,000 Miles (197,907 Kilometers)
Total:26,000 Miles (41,834 Kilometers)
    As of 10/15/2021
Seating Capacity4
Curb Weight2,050 Pounds (931 Kilograms)
With Li-Ion it is 40kg lighter than with NiCads.
Tires165/70 R13 75T, all year.
Conversion TimeConversion only in the meaning in change of
the battery took me approx 200hours
Conversion Costapprox 6000USD
Vehicle bought in 2016 with 97000km. It was in original state with
20 NiCd SAFTs giving range approx 70-80km in summer. Summing the
past 4years, I gained quite much experience with it and apart the
fun it gives me for sure experienced also several big troubles
explained further.
After 10000km driven, 3 SAFT modules died so I have bought another
used ones and replaced them.
After another approx 12000km another 3 blocks died so I gave up on
this chemistry and as we love the car we decided for a Li-Ion
upgrade as I'm more familiar with them and had the possibility to
buy quite cheap cells in a perfect condition.
I have disassembled the batteries in 12/2019 and few months
working on it.
Unfortunately, after batteries were ready and mounted on the
vehicle I also replaced the brushes and managed to fix them in a
wrong position which caused motor and Sagembox burned during the
first test drive.
Fortunately to another guy from Evalbum I managed to buy another
motor in pre-restoration state (bad iso state, oil leakage, many
many carbon-oil dust in it). I gave it to one guy who deeply
cleaned it, did new winding paint in a vacuum chamber and replaced
all the ball bearings also with sealings. Before the isolation
state was like +-0,5MOhms, now is probably higher than 5,5GOhms,
so motor in a great condition.
I also managed to repair the burned Sagem box thanks to one guy
who has long experience doing it.
Therefore the car was dead more than 1 year, almost whole 2020.
To be able to drive longer trips I have completed a fast charger
using 6 pieces of Eltek Flatpack 48V/1500W power sources connected
in 3s2p giving in total 9kW of DC power. This setup makes me able
to charge the full capacity of 27kWh in approx 2hours, so like
100km/hour. Batteries seems to be almost not heating themselves
during charging/drive due to very low internal resistance and also
quite low charging/discharging currents topping maximum of
200Amps. Therefore I decided not to deal with cooling, but this
summer will show :)
Regarding range, I have not tested it yet fully, but longest trip
I made was in conditions of approx -3°C, 70%highway/30% country
roads, some battery heating needed, 150km total driven and there
was still energy left in the battery. Therefore I'm hoping for
summer range to be at least 200km+.

code by jerry