Camira Conversion

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jstan
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Camira Conversion

Post by jstan » Mon, 13 Jul 2009, 16:23

Re the size of Generator needed for unlimited driving. My way is not very efficient as I am running the 240 Volt AC back into my chargers which can only put out 18AMPS. Probably my 13 HP 5.5 KVA generator would keep you going if you ran the AC through a bridge rectifier to convert it to DC and then feed it straight into your batteries or motor. I am not a tech and am unsure of the results if you did this, the batteries would take the 240 volt and treat it as 140 or whatever your battery bank voltage was but then you would have to have a BMS to avoid overcharging and I am not sure how the motor would react to a higher voltage. All you techs out there, what is the answer?.
John
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Post by jstan » Mon, 13 Jul 2009, 16:44

Re generator size. I opted for the simple and safe way, that is I fed the 240V AC into my chargers therefore I could only get 18 AMPS. Probably my 13 hp. 5.5 kva would keep you driving. If you put the 240V through a bridge rectifier to convert it to DC then the battery pack should accept this as whatever Voltage is in the pack, you would need to rig the BMS to prevent overcharging, and I don't know what effect the higher voltage would have on the motor. I am not a tech so a call to all you techs out there, how could this work?
John
EDIT I thought that I had lost my first post so did it again now you have two.      John
Last edited by jstan on Mon, 13 Jul 2009, 06:47, edited 1 time in total.
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coulomb
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Post by coulomb » Mon, 13 Jul 2009, 16:49

Just rectifying 240 VAC would give pulsating DC from 0 to about 340 V, which is not suitable for direct connection to the pack.

It may be possible to replace a 3-phase alternator with one that produced lower voltage, and 3-phase AC rectified (6 diodes) is not so bad for charging with. You would alter the field excitation to the alternator to produce distorted sine waves that rectified to almost pure DC, and would to the CC/CV control via the alternator average field current.

I wonder if anyone has tried that. It would possibly work best for a high voltage AC pack (~600 VDC nominal), since that would not require modifying inside the alternator, just the control circuit driving the alternator field. That way, you'd get the most from the alternator, and avoid most of the losses of AC to DC conversion.
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jstan
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Post by jstan » Wed, 15 Jul 2009, 01:04

For anyone interested in Li-ion batteries I did a test today on a run to our local shop.
18 km round trip used 22.83AH therefore my 90AH pack should go 70.96KM , in the summer I was working it out at 75KM, I don't know if the drop in Kms is due to the batteries being one year old or the colder weather.
My car is a camira station wagon the motor is Advanced series wound DC 9" and at present I am using a logisystems 144V controller.
I get my readings from my Pitronik chargers, you can read the AH for the last 32 charges, I use 3 48Volt chargers and split my battery pack into 3 packs of 15 batteries each. At the time of build (four years ago) it was cheaper to buy three 48V chargers than one 144V one.
John
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Richo
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Post by Richo » Wed, 15 Jul 2009, 06:53

jstan wrote:18 km round trip used 22.83AH therefore my 90AH pack should go 70.96KM


If you did 100% DOD.

Also 144v x 22.83Ah = 3287Wh
3287Wh / 18km = 182Wh/km

Which is quite good.

The variation in range could be a result of both cold weather and one year of use.

What about accessories?
Are you using a heater in the winter time or have the lights on more?
So the short answer is NO but the long answer is YES.
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jstan
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Post by jstan » Wed, 15 Jul 2009, 16:21

Richo
No accessories no lights no heater, but I am still quite pleased
John
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Post by jstan » Fri, 17 Jul 2009, 03:14




I have just finished a new parts list, I can't work out how to post it to here however here is a summary, the complete list will be posted on Paul's forum.
John


Mouser Total        US$33.29 AU$58.90
Plus Shipping of US$30.00=AU$37.50 AU$96.40
If four people combine the shipping is a flat rate so four into AU$37.50 = AU$9.38 plus AU$58.90 =AU$68.28

Digi-Key Total     US$200.37AU$251.00
Plus Shipping AU$90.00 =   AU$341.00
If four people combine the shipping is a flat rate so four into AU$90.00 = AU$22.50plus AU$251.00=AU$273.50
               Based on conversion at 9 30pm 16/7/2009                    

Total cost does not include boards
Indivindual orderMouser AU$58.90Shipping AU$37.50Total AU$96.40
          Digi-Key AU$251.00Shipping AU$90.00Total AU$341.00
               Total-----------AU$437.00

Four people combine Mouser AU$58.90Shipping AU$9.38Total AU$68.28
          Digi-Key AU$251.00Shipping AU$22.50Total AU$273.50
               Total-------------AU$341.78

Mouser has free shipping to Aus. For orders over $200 if you order in AU$ however their prices for buying in AU$ are quite a bit higher than buying in US$.
Shipping parcels should be kept under $1000.00 , over this attracts Customs
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Post by jstan » Sat, 18 Jul 2009, 04:52




I can blame it on age or rusty brains however I got it wrong last time, I mixed up the prices Mouser charge for AU$ orders free shipping and their price if you elect to pay US$ . Here is my revised list prices. Of course the more people to share the cost of shipping the cheaper per person.
John

Mouser Total        US$33.29 AU$41.43
Plus Shipping of US$30.AU$37.50                    AU$78.93
If four people combine the shipping is a flat rate
so four into AU$37.50 = AU$9.38 plus AU$41.43          AU$50.81
For Mouser prices AU$ with free shipping AU$58.90
if four or more people order                            AU$58.90
Digi-Key Total     US$200.37 AU$251.00
Plus Shipping AU$90.00 =                      AU$341.00
If four people combine the shipping is a flat rate
so four into AU$90.00 = AU$22.50 plus AU$251.00     AU$273.50
               Based on conversion at 9 30pm 16/7/2009                    AU$308.50

Total cost does not include boards
Individual order     Mouser AU$41.43          
Shipping AU$37.50     Total AU$78.93
               Digi-Key AU$251.00          
Shipping AU$90.00     Total AU$341.00
                         Total-----------AU$419.93

Four people combine   Mouser AU$41.43          
Shipping AU$9.38      Total AU$50.80
Four people combine Digi-Key AU$251.00          
Shipping AU$22.50     Total AU$273.50
                         Total-------------AU$324.30

Mouser has free shipping to Aus. For orders over $200 if you order in AU$ however their prices for buying in AU$ are quite a bit higher than buying in US$.
Shipping parcels should be kept under $1000.00 , over this attracts C
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Camira Conversion

Post by johnstan » Mon, 14 Jan 2013, 20:18

My last post was May 2009, since then my house has gone almost completely off grid but the car seems to be unsuitable for rural use.
I have come to the conclusion that my EV was not suited to my rural area, that is return trip to Bairnsdale being about 60 km. At first I struggled to do the trip but as the batteries got older I had more problems and tried to boost my capacity by fitting a set of 40ah lithium in parallel with my 90ah set, this did not work as it seems that the 40ah set could not cope with my 200 amp demand and they started to fail.
I continued to use the car with the 90ah set for shorter trips but then I suffered a setback when one of my chargers (I use three 48 volt chargers) failed and drained 15 of my 90ah batteries to 0 volts thus killing them, I have continued to use the car for short trips with only the remaining 30 batteries but that seems to be to much of a strain and I now have 2 more batteries fail and I assume that I will have more fail if I continue to use the car.
I have decided to sell my car or the various parts.
I have 28 90ah lithium batteries, 40 40ah lithium batteries, 45 bms units working on the 90ah set, 45 bms units need checking working on the 40ah set, the controller is a Cougar digital high voltage controller , my motor is a 9” series wound high voltage DC motor, my drive is manual gearbox with no clutch, my vacuum brake system is powered by a 12 volt vacuum pump,
If I was to keep the car I would discard the 2 remaining 48 volt chargers and purchase a single high voltage (160volt) charger, I would discard all the existing batteries and buy a set of 45 120ah or bigger batteries.
Please give me your thoughts on what price I could expect for my car as is or make an offer. I would welcome any prospective buyers test drive and any other examination and I will try to point out any problem areas.



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