Redback Hybrid Inverter Trial
We have commenced a trial of a Redback Hybrid inverter with EV PowerPak batteries.
Redback have created a "Custom" battery type which allows some tailoring of the charge system to suit independent batteries.
This system is larger and costs less per kWhr than the imported batteries available from most solar suppliers. It allows the residence to effectively be completely off-grid for self consumption but still export excess solar energy back to the grid. How green can you get?
Custom Kimberley Kamper 240Ah battery install
August 2016 - Customised battery pack retrofit for Graham S. Kamper Platinum. Older model.
18kWhr 100V Battery Pack
June 2016 - 200kg with full battery management system.
MARINE ELECTRIC DRIVE UNIT
We are doing some work to design a marine drive unit with selectable ratios for use with Motenergy motors and Sevcon controllers. It features seemless transition from Forward to Reverse as well as Valet Mode and regeneration charge under sail. Version 1.
A Little Power Tower for a Solar Customer
Feb 2016 - Here is an example of our rack mount battery solution for an off-grid customer using Schneider XW inverter and MPPT. 400AH @ 52V, 20kWhrs of storage.
Up to 10kW of power is available from the batteries (5kW continuous).
The small footprint (950mm x 450mm x 1750mm tall), weight (260kg), Cycle Life (>2000 @ 80%DOD), usable capacity (16kWhrs every day) and price compare favourably with other Lithium systems and also with high end Lead Acid systems such as the Ecoult UltraBattery.
The best part is that all the components are easily transported, easily assembled and can be carried in to the installation venue!
Custom Battery Pack
The EV Power team engineered and fabricated this 350VDC 62kWhr battery pack for a commercial customer. It has an integrated 4kW charger and BMS with CANbus communications.
It is also liquid cooled and features finger proof connectors.
EV POWER TOWER EVOLUTION
After 12 months continuous testing our "EV Power Tower" grid free solar storage system has developed with 25kWhr of storage. We use a 5kW inverter but the Lithium BMS is inverter independent so almost any model can be chosen.
Grid Free - The Sky is the Limit !
Sunflower Solar Power Trailer
Southern Cross University created this trailer a few years back that uses EV Power LFP batteries. It supplies power for stage lighting and sound at music events. No noise, completely renewable.
EV Power is Electricity Grid Free
At EV Power we use the products we sell every day. We generate enough power to run our workshop and charge two full size electric vehicles for local transport. To put it a different way. We no longer pay for our power or for fuel for our cars. It is all FREE FROM THE SUN and should be the right of every Australian since we live in a sunny country. The electricity grid is still connected to the premises for now as a backup supply should it be required. We look forward to disconnecting it completely in future.
Electric Racing Kart Prototype
After some weeks of design and construction we wheeled out an electric racing kart just in time for the annual WA Electrikhana. Running 80V nominal into a Sevcon Size 2 controller mated to a ME1114 motor with belt drive to the rear axle. Headway 24S1P 15Ah battery pack delivered 120A+ with no fuss. EV Power 12S BMS. Designed with right foot throttle and left foot regen braking it has a serious turn of speed even though it was only roughly tuned. The mechanical brake was never really activated so good was the regen.
Electric Proton Jumbuck Mark III
We recently completed our third and by far the best Proton Jumbuck to EV conversion. Lucinda and Simon routinely drive 150km+ on a charge.
AC motor with regen braking, 29kWhr battery. Fully licensed and street legal.
Small Custom Engineered Battery Pack
We recently designed some 12V 15Ah batteries complete with BMS for a customer.
Electric Farm Vehicle
Recently EV Power supplied parts and assisted in the construction of a prototype vehicle.
- 45 x CALB CA100FI cells with CM090 cell modules and BCU-PEV-45C
- Dual GLE IM15 AC induction motors, 150V 300A 6000rpm each
- Belt driven rear wheels
- vehicle weight < 500kg
- stunning performance!
Lithium Off-Grid Solar System
Another first! Simon and Kylie Lucas have installed an off-grid domestic power system in South West WA. We are reliably informed this is the first CEC approved Lithium battery powered system of its type in WA.
EV Power supplied and installed the 48V 27kWhr battery pack which is notable for its small footprint, light weight, low maintenance and simplicity of installation. The solar installers could not believe their eyes when the pack was delivered in the back of an electric ute, a Lead Acid battery would need a truck!
A 7kW inverter is installed and 9kW of Solar panels also supplied by EV Power.
CCTV Trailer Battery
We installed a 12V 2000Ah battery pack with chargers in a CCTV camera trailer.
Large Scale LFP Battery Pack for Uninterruptable Power
EV Power recently delivered battery packs for a large industrial Uninterruptable Power Supply. At 420VDC and 168kWhr of storage capacity this is our largest single system to date.
Peak/Off-peak Load Shifting Uninterruptable Power Supply
We are trialling a "load shifting UPS" project. Load shifting means charging batteries during the off-peak period at night when grid electricity is low cost. Then power is consumed during the day from the batteries via an inverter.
It is effectively an Uninterruptable Power Supply which additionally supplies off-peak electricity. In effect it removes the requirement for high maintenance back up generators.
This system will test the reliability of the CALB batteries over a period of continuous deep cycles (50-70% DOD per day). In the picture is a 5kW inverter/charger and 16 x CALB180FI cells using the EV Power battery management system. Approximately 9 kilowatt hours of storage. The net energy cost saving is about $1.80 per day.
This is well suited to facilities that require uninterrupted 240V power and it offers the significant advantage of electricity always being supplied at off-peak rates.
As usual EV Power leads the way on practical usage of LFP batteries.
Electric Bus Battery Pack
Crown Coaches in Melbourne are quietly leading the electric bus revolution in Australia. They have a small fleet of Chinese made electric buses which are in daily use for school runs around the metro area.
One the the early models was having trouble with the battery in that it would drift out of balance after a few charges because the BMS employed had no balancing function. It required manual balancing of about 200 cells in all.
EV Power was contacted to find a solution and the EV Power BMS was ultimately employed to useful effect.
Remote Area Power with Lithium Batteries
System for a weekender. 4.5kWhr capacity with 3kW inverter charger. 160W solar for trickle charge. Honda iU20 for fast charge.
Electric Proton Jumbuck Mk-2
In-house project. This is our second Jumbuck conversion. Using a GLE MP20L1 AC permanent magnet motor and 90 x CALB SE100AHA cells.
BMS BCU-PEV-90C master unit with display.
Electric Wheelchair Conversion SLA to Lithium
We have now converted two of these four wheel drive wheelchairs to LFP batteries. The owners immediately gain an experience of increased freedom and confidence due to the extended range allowing a full day of mobility. The chairs become considerably lighter and more manageable as well.
VMOTO E-MAX 110S Conversion to Lithium
Customer project - We doubled the usable range with LFP batteries weighing just 36kg. The original SLA batteries were 90kg!!! As a result the bike handles soooo much better, and goes faster too.
Kimberley Karavan Conversions
Recent conversions of Kimberley Karavans from Lead Acid to LFP batteries.
WEATHERPROOF BATTERY PACKS
EV Power was recently contracted to design and build a number of weatherproof battery packs for a corporate client.
- 100Ah 12V, LFP
- Lightweight, less than 15kg
- Pole mount with quick release for off site charging
- Weatherproof IP54
- Rugged design
- Inbuilt battery management
These battery packs have potential marine application also.
REMOTE VIDEO SURVEILLANCE CASE
We have been contracted to assemble video surveillance kits for a corporate client. The kits are used in a range of situations for remote observation and are rugged and weatherproof. This involved a comprehensive design process for the battery/charger system we supplied. Design also included the plastic insert/separator to protect the LFP battery, BMS and charger. The insert also supports the PC.
The EV Power Tower
We recently completed a project for an energy utility company. For fringe of grid stabilization, its nicknamed the EV Power Tower.
- Aluminium Enclosure with front and rear three point lockable doors.
- 1030 x 910 x 1600mm
- 600 kg total, 39kW hrs nominal energy storage capacity
- 400VDC nominal
- up to 50kW hrs max available usable storage capacity
- System voltage and capacity can be varied to user requirements
- Space for up to two 19" Rack mount solar regulators/inverters/chargers 6U (267mm) high
- Battery management system, fuses and DC contactors built in
- Small foot print for the capacity. Lead acid systems could not come near this.
Mining Application for EV Power Paks
EV Power recently supplied 16 EV Power Paks to a large mining company for telemetry systems.
AC Motor powered Electric Vehicle conversion
- Car - 2004 Proton Jumbuck GLSi 5sp manual
- Motor - Synchronous AC Permanent Magnet motor, BLDC, air cooled
- Inverter - 80kW 312V VF Drive controller, air cooled
- Have seen 300A peak at 270VDC ==> 81kW actual
- Battery - 90 Cells LiFePO4 90-100Ah, 288-300VDC nominal
- Charger - Elcon 2.5kW, 288V
- Battery Management - EV Power BMS of course!
- Steering pump - Mocen 24V 500W hydraulic
- Vacuum Brake pump - BetterVac 12V
- DC-DC 12V Aux power - Meanwell Switch mode power supply 36A (no aux battery)
- Instrumentation - Xantrex Pro, Volts, Amps, Ah, time remaining till empty.
- Battery Capacity 25kWhrs
- Range - 150km @ 90kmh
- Top Speed - 140kmh +
- Acceleration - significantly faster than IC version
- Gearbox - retained but no clutch, generally only 2nd and 3rd gears required. With some modification to the inverter no gears would be required.
- Economy 155Whrs/km Highway.
- First drive in Oct 2009
Lithium Powered Golf Cart
I took a 36V EZGO golf cart, removed 156kg of Lead Acid and installed 70kg / 48V of LiFePO4 batteries. This is the result...
- EZGO Golf Cart
- Controller - 48V Series/PM 300A (original was 36V Curtis)
- Old Batteries - 6 x Trojan T105, 156kg, 5.7kWhr (5hr rate)
- New Batteries - 16 x SE130AHA, 71kg, 6.8kWhr (1 hr rate)
- Battery Management System - EV Power of course!
- Charger - PFC LiFePO4 16 Cell 25A
- Charge time - 5 hours from Empty
- Top speed - 25kmh
- Lithium battery weighs less than half the lead acid battery.
- 20% extra range
- 25% higher top speed
- 2000 deep cycles Lithium versus 300 deep cycles Lead Acid
Whatever way you look at it LiFePO4 batteries are a clear winner!
CERES ELECTRIC VEHICLE
EV Power supplied BMS and components to CERES in Melbourne for their first EV. Rhys Freeman has been the driving force behind this project and has seen it all the way through from concept to fruition.
University of WA Renewable Energy Vehicle Project
EV Power Pty Ltd supplied batteries and BMS for the first UWA Renewable Energy Vehicle in 2007.
This vehicle has assisted UWA to obtain much needed sponsorship funds for further EV research.
Swan TAFE EV Challenge 2008
EV Power sponsored the "River Raiders" team this year in the Swan TAFE EV Challenge. This is an electrathon style of event where vehicles race for one hour around a winding circuit. At the end of the hour the numbers of laps are compared.
The team consisted of Rod Dilkes (electrics), Wayne Pragnell (body design) and Peter Fitchat (steering/suspension).
In all we entered three cars in two classes:
Electric Chair - Yuasa Class (No cost limit, SLA batteries provided)
Carbonnay - C Class (Open class, $1200 cost limit)
Hot Rod - C Class, Yuasa class
The results for our team were as follows:
C Class - 1st Hot Rod, 3rd Carbonnay (also engineering award)
Yuasa Class - 1st Electric Chair (also engineering award)
We wish to thank all the teams and the organizers of this great event. As all the teams well know 95% of the effort is in just getting to the start line! We hope to see it grow and promote the use of EVs in the future.
The cars used hub motors and brushless controllers. Batteries were LiFePO4 400Whr capacity, 4.2kg. The first three cars in the C class were powered by LiFePO4 battery packs supplied by EV Power, LiFePO4 batteries are our specialty.
A short clip of the Swan TAFE EV Challenge coutesy of Wayne Pragnell is available here
Congratulations go to South West Regional College of TAFE who came second in C Class using EV Power batteries. Also to Donnybrook Senior High School who came second in Class A using an EV Power hub motor/controller. Well done guys.
By using Grid connected solar power we now effectively have a solar powered car!
Solar Assisted Electric Vehicle
In 2003 work began on an Electric Vehicle. A Suzuki Mighty Boy was converted from petrol to electric and has been used daily ever since. In Februrary 2007 Thundersky LFP90AHA Lithium Ion batteries were installed. These batteries mark the beginning of the Electric Vehicle revolution.
In August 2007 a grid connected solar array was mounted on Rod’s home. The car is charged using off-peak power at night which the solar array generates during the day. It also gets some charge from a solar panel mounted on the roof of the car itself. As such it is the first and only completely solar powered commuter vehicle in Australia.
Lithium Ion Battery Management System
The Battery Management project began in mid 2006. After examining all the available options it was decided that a simple but failsafe solution was the best course of action. Extensive prototyping was embarked upon and finally a design established. This BMS has been tested extensively in the Suzuki Mighty boy since Feb 2007.
As of July 2008, the BMS cell modules are being mass produced. The design has been through several iterations and is finally mature. Check our products pages for info and pricing.
Conversion to Thunder Sky LFP90AHA Batteries
In February 2007 the Suzuki Mighty Boy was converted to run on Thundersky LFP series Lithium Ion Batteries. This was the first such installation in Australia. As of Feb 2008 the car has done 8000km of faultless service on these.