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Sydney Builder

Posted: Mon, 07 Jan 2008, 02:10
by a4x4kiwi
Hi,

I am Malcolm Faed and am currently embarking on the ambitious project of converting a van.
My blog is available via the link in my sig.

I am interested in meeting any other builders on the northern beaches of Sydney and of course the Sydney club art the next meeting.

Regards,
Mal.

Sydney Builder

Posted: Wed, 09 Jan 2008, 01:01
by Mark T
Hi Mal
Great to see someone in Sydney using the website. I am also converting a van, a Suzuki Carry. Look forward to talking with you at the next meeting, Feb 5th.
Mark

Sydney Builder

Posted: Mon, 14 Jan 2008, 16:56
by a4x4kiwi
Hi Mark,

Likewise.

What year is your Van? I took a look at 2002? carry (The long bonnet version.) My motor is quite tall and it wouldn’t fit. The ICE is tilted at 45% to lower the profile.
I am sure a DC motor would fit nicely in this model as they are significantly smaller. It should have a good power / torque to weight ratio. Also I want to retain the rear seats and the batteries would need to be on the high section of the floor raising the CG. If this model, and don’t need the rear seats, your van should be Excellent!

See you in Feb.

Cheers,
Mal.

Sydney Builder

Posted: Thu, 17 Jan 2008, 03:08
by Mark T
My carry is an old 1990 model. I'm attempting to fit all 15 batteries under the floor. It's a tight squeeze but I love a challenge Image

Sydney Builder

Posted: Fri, 08 Feb 2008, 18:05
by Barrington
Hi Mal,
We spoke the other night at the AEVA meeting and you mentioned that you were looking for a Variable Speed Drive for the AirCon. I mentioned a small one I saw on eBay and its up for auction again, though its more expensive than I remember. He had it up several times so maybe he might be up for some negotiation(?)
eBay Danfoss Link

There certainly have been smaller ones like this AB unit:
eBay AB Link
I have been looking to see whether there were any in the 15-20kW range and the price.

Sydney Builder

Posted: Fri, 08 Feb 2008, 18:13
by a4x4kiwi
Hi, Thanks for the links.

There is an 18.5 Kw Allen Bradely 1336 Plus unit at M&E Equipment.

It would need testing as it looks like it may have been dropped but if it works it would be a good unit.

They can test it before you buy it. The last price I was last offered was $1300

Check my blog as I have document some schematics using that drive.

Regards,
Mal.

Sydney Builder

Posted: Fri, 08 Feb 2008, 18:32
by Barrington
Thanks Mal,
I just saw a post by Tuarn suggesting you could pick up NEW motor for half that:
acmotor wrote:I bought an 11kW 4 pole for $250 S/H (an older heavier 80kg unit) But also priced a new WE motor at $535 + GST from New Era in Welshpool.

It looks very promising.

A VSD is the next step!
Do you happen know if they all inherently provide regen braking or is that a feature you specifically have to look for?

Sydney Builder

Posted: Sat, 09 Feb 2008, 00:44
by a4x4kiwi
Hi,

He got quite a bargan. I think this kind of thing is more plentiful in WA.

Look for a DC bus and regen on teh drive but that is not the only thing.

When you find a drive, you will have to download the manuals to ensure it has all the inputs, outputs, ratings, analog pot interface and features you require.

Plan to spend a few days worth of reading on the drive and planning how it will interface with your design. Each drive differs enough to be significant. Look for rated current, overload current, DC bus limits compared to battery pack voltage, control modes, open / closed loop. There are a lot of things to consider.

When you read the manual you want to be identifying what each input and output will be used for and also at least mentally determining what each of the software parameters will be set to.

Anyway, take your time and enjoy the process.

Image

Regards,
Mal.

Sydney Builder

Posted: Wed, 05 Mar 2008, 08:33
by Mesuge
Hi from my understanding, the AB 1336 units usually need to add:

1/ brake chopper module
2/ brake resistor
3/ RFI filter module (as Australian tech. inspection seems to be as hard as in the EU - while american authorities don't bother to meassure anything as such during their EV - street legalization process hah)
(4) communication module if you are about this Modbus/Profibus/PLC network thingy to channel every bit of info into one data stream, be it for online dash or saving the data for later diag..

=> so to wait and snap another Danfoss VLT/FC with all (3) options in one made in their factory could be a better bet..

--
Btw. there seems to be another contender for the most affordable VFD drive for EVs, it's called Teco-(Westinghouse) and it is a Taiwanese company, perhaps with mainland factories. The pricing for their 30-40kW units is very seducing, I think upto 25hp models the brake resistor is included, also it sports Modbus comm. card, lots of relay & I/Os, very good manual, free diag software, etc..

Blog about MGB conversion using Teco drive:
http://kermitthecar.blogspot.com/2007/0 ... -here.html

Sydney Builder

Posted: Wed, 05 Mar 2008, 10:11
by a4x4kiwi
Hi Musuge,

For the AB, the chopper and brake resistor are one unit. See my blog for a picture.

RFI, I doubt they do any checks at the inspection.

Networking, yes you need the communication module. The Danfoss already has one.

I have assessed a few models over time and most meet the requirement. It then comes down to the detailed features, price and availability.


Something I have been thinking about is not using the braking resistor and enabling the setting to delay the braking time if the bus voltage exceeds a threshold. The important thing is that the voltage threshold is equal or less than the maximum cyclic charge voltage for the pack. This is dependant on the controller.

The implication is that when you are going down hill or slowing down on a full charge you will need to use the brakes more than if the batteries were discharged. It might make the regenerative braking a little unpredictable.

Cheers,
Mal.

Sydney Builder

Posted: Wed, 05 Mar 2008, 10:15
by a4x4kiwi
Hi,

i just realised that I didnt answer your question.

I think all AC drives provide regen, but you may have to add a DC bus sharing option. On the Danfoss this can be done after the rectifiers and before the soft charge device.

Cheers,
Mal.