INTRODUCTION
Thank you for your interest in Electric Vehicles of America, Inc. (EVA).
This catalog has been prepared to assist you in starting your EV Experience.
We want to share our ideas and experience to help your EV experience be
enjoyable. We ask our customers "Are you having fun?".
Their response is: Yes! We are!
If you do not see what you need in our catalog, please contact us.
We have listed the most popular components. Curtis PMC makes hundreds of
different controllers; Albright manufacures many different contactors.
And we are always adding new components.
EXPERIENCE
EVA was founded in 1988 to serve individuals, high schools, colleges,
businesses, and electric utilities. We share our experience in:
• SAFETY. EVA is the leader in EV safety.
• QUALITY COMPONENTS. We only sell it if we will use it in our own conversions.
• EV CONVERSIONS. Our conversions include trucks, cars, vans, and more.
• SERVICE. EVA is the leader in Customer Service. You are No.1 !
Our customers include:
Government Commercial Education
U.S.Air Force Long Island Railroad MIT
Tennessee Valley Authority John Deere Company Harvard
Cleveland Electric North Carolina Dept of Transportation RPI
Jersey Power & Light Briggs & Stratton Cornell
Kansas City Power & Light Hewlett-Packard Texas A&M
and hundreds of other businesses, colleges, high schools, and individuals in the U.S.. Europe, and Asia. We believe that the customer deserves the very best in both service and components.
DESIGN CRITERIA
A good design is the result of careful consideration of each component and its potential impact on the safety of the overall vehicle. Therefore, it is important to establish your safety criteria.
At EVA, our criteria for a safe design is:
• Design for a "Single Failure". No component should jeopardize safe operation!
• Provide "redundancy" of safety components (e.g. fuses, contactors, etc.)
• "Separate" high voltage components, especially the positive and negative side.
• Allow accessibility around components so maintenance can be performed safely.
• Keep high voltage power cable out of the passenger compartment.
Next, we developed engineering criteria.
• The vehicle must accommodate the weight of the batteries.
• The batteries should be located outside the passenger compartment and restrained.
• A small passenger compartment will minimize heating and/or cooling requirements.
SELECTING A VEHICLE
To help you select an EV to meet your needs, we provide the following guidance:
• Define the propose for your vehicle and its design features. Define its daily range, loads, typical speeds, terrain, weather conditions, etc. Will you use it for commuting? Will the vehicle be kept in a heated garage overnight? Will your employer let you charge?
• Review the vehicles manufactured that might meet your requirements.
• Select one or two specific vehicles. Compare their weights, available room for batteries, rolling resistance, aerodynamic drag, and other characteristics.
EVA has written a technical paper "Selecting A Vehicle for Conversion"; this paper is available via E-mail.
SELECTING COMPONENTS
You will invest thousands of dollars in your EV as well as many hours. These guidelines are offered to help you select components:
• Large diameter motors are more efficient.
• The peak horsepower of a motor is 2-3 times its continuous rating. (nameplate)
• Every 1000 lbs of vehicle weight requires approximately 4-6 hp continuous.
• Higher voltage provides better acceleration.
• Range is a function of pounds of fuel, in this case, the fuel is lead. The more fuel the greater your range, but the heavier the EV.
In addition to the basic components, you will also need contactors, instrumentation, cable, lugs, and more. These additional components are critical, because they directly affect performance. For example, using poor quality lugs and undersize cable can decrease your range by as much as 50 percent!
FINALIZING YOUR DESIGN
At EVA, we will assist you in selecting the best EV component package by:
• Performing EV calculations comparing various designs (vehicles, voltages, batteries)
These calculations are available via E-mail.
• Developing a detailed quotation. This is also available via E-Mail.
BUILDING YOUR EV
EVA will assist you as you build your EV by providing our "EV Installation Guidelines" and "Safety First" video. The guidelines include installation instructions, manufacturer's drawings, electrical schematics, arrangement drawings, and more.
Most important, we are as close as your phone. If you have a question during the conversion, just call. We are always available by phone, FAX or E-Mail at EVAmerica @aol.com. We are here to support you and make your EV the very best!
EV COMPONENT DESCRIPTION
Advanced DC Motors
Advanced DC Motors are series wound DC motors specifically designed for EV applications with high efficiency and peak performance. Motors range from 24-144 V and 2-30 hp continuous. Peak horsepower is 2-3 times continuous. Motor Curves are available via fax.
Adaptor Plates and Couplings
Our unique clutchless design allows easy conversion of all vehicles. The design eliminates the clutch and the flywheel and uses a direct drive to the transmission. This minimizes weight and potential overspeeding of the motor. Gear changes can be made because there is no inertia to the electric motor. This design facilitates the conversion of vehicles that had an automatic transmission, because the clutch does not have to be installed.
Curtis Controllers
Curtis are designed for series wound motors with voltages from 12-144 V. Features include:
• Current Multiplication
• High Speed switching
• Current Limitation
• High Pedal Protection
• Low Voltage Protection
• Runaway Protection
Potboxes
The accelerator potentiometer or potbox translates the mechanical movement of the accelerator pedal to an electrical control signal to the controller. Curtis has a wide range of potboxes. The standard PB-6 is right hand operation; the PB-9 is left hand. The PB-6 and PB-9 come with a micro-switch. The ET-103 and ET-Marine allow forward/reverse operation in a single assembly.
Trojan Batteries
Trojan batteries provide long life, have a greater water reservoir, and are quality constructed. EVA customers have achieved 18,000 -20,000 miles on a set of T-145 batteries. Battery life is directly related to how they are used and maintained. EVA will gladly help you select the best battery for your application and vehicle.
Weight Minutes Dimensions
Battery Voltage (lbs) @75amps Length Width Height
T-105 6 61 105 10-3/8 " 7-1/8 " 11-1/4"
T-125 6 66 125 10-3/8 " 7-1/8 " 11-1/4 "
T-145 6 72 145 10-3/8 " 7-1/8 " 11-1/2 "
T-875 8 63 75 10-3/8 " 7-1/8 " 11-1/4 "
SCS225 12 66 57 13 " 6-3/4 " 9-1/4 "
Battery Boxes
EVA can fabricate black polyethylene battery boxes specific to your design. These batteries are light-weight, strong, and non conducting. Insulation is added to improve range in cold weather.
DC/DC Converters
DC/DC Converters charge the 12 V auxiliary battery by converting the voltage of the battery pack. They maintain head light brightness, a safety feature. They are the equivalent to an alternator in an ICE vehicle.
Albright Contactors
Contactors are required to turn the high voltage system on and off. Contactors come with magnetic blowouts for on-road EVs and with protected enclosures for marine applications. Albright makes several hundred different contactors. We stock the most popular for immediate delivery. These include on/off and F/R contactors.
Lester Chargers (Off-Board)
Lester Chargers are fully automatic chargers with patented electronic timers which sense the charge condition of the batteries and charge them fully and properly charged every time. Many models come with both 115 VAC and 230 VAC capability. 230 VAC provides a faster and more complete charge.
K&W Chargers (On-Board)
These chargers can be located on-board to charge light-weight battery packs (<1000 lbs). The BC-20 is available for 48-108V systems; higher voltages require the LB-20 to boost the input power to the BC-20.
Instrumentation
Ammeters and voltmeters help you drive efficiently. Standard meters are 60-160V and 0-400 amps or 0-500 amps. Automotive style meters (2 inch) are backlit. Special meters can be made for your specific requirements.
Curtis fuel gauges identify the status of your battery pack. With 10 LED increments, driving confidence is gained. The 900R is directly connected to the battery pack; the 968 is programmable and provides isolation between the high voltage power and the meter.
The E-Meter combines the ammeter, voltmeter, and fuel gauge in a single unit. The base unit with filter and shunt is designed for 50 Volts. A prescaler allows higher voltages to 500V; a DC/DC converter provides isolation from a grounded 12V system.
Vacuum Equipment
Required to maintain your power-assisted brakes. The 12V pump operates automatically thru the switch. The vacuum gauge assists in initial installation.
Control Wiring
EVA uses cross-linked automotive wire and can fabricate a wiring harness with AMP disconnects for your EV.
Power Cable & Lugs
Our lugs are plated and 80 percent heavier than standard lugs. This minimizes the resistance and improves range. One customer got a 30 percent increase in range just by switching to our lugs!
Our design uses flexible welding cable (available in black and red), heavy duty plated lugs, heat shrink with sealant, and industrial crimping tools. Only the best! Why spend thousands on an efficient motor and controller only to lose that energy in poor connections!
Safety Components
EVA is the Leader in EV Safety using .......
First Inertia Switch opens the contactors in case of an accident. This shuts down the power to the controller and motor. The power is off! A must on all EVs!
Anderson connectors for the power cables disconnect easily to perform maintenance. We disconnect our Anderson every time we open the hood; eliminating power to all high voltage components. Nothing is live!
Our high voltage fuses are designed to operate in the short circuit condition. No nuisance blows during acceleration. A fuseholder is available.
EVA fuses control circuits and the 12V wiring with a unique 4-fuse holder for mounting on the control board or an in-line fuse holder.
MDO Board (3/4 inch thick) is used to mount our electrical components and maintain isolation between electrical components.
TRUCK CONVERSIONS
EVA started the truck conversion market in 1990. We selected trucks because their:
• Payload capacity is greater.
• Curb weight is similar to many cars.
• Cab size minimizes heating.
Unique features of our design are:
• Tilt bed construction with the batteries under the bed. This lowers the center of gravity, provides better crash protection, and allows full use of the bed. It remains a truck!
• Our electrical components are located on MDO board over the motor. The board can be removed in 5 minutes; the motor in 30!
• The control board is hinged so it tilts up for easy inspection of the motor.
• Four separate battery boxes minimize exposure to less than 48 volts when performing battery maintenance.
Customers using our truck design include:
• The U. S. Air Force (Hanscom AFB)
• Bangor Hydro-Electric (ME)
• Chicopee Municipal Light (MA)
• Cleveland Electric (OH)
• Commonwealth Electric (MA)
• EcoElectric Corporation (AZ)
• Jamestown Electric (NY)
• Lincoln Conservation Commission (MA)
• Marblehead Light (MA)
• Nevada Power Company (NV)
AUTOMOBILE CONVERSIONS
Although automobiles are limited by their Gross Vehicle Weight Rating (GVWR), they can be safely converted. If the GVWR is exceeded, the vehicle is there will be additional brake wear, handling problems, and possibly structural failure. Therefore, automobiles can sustain only light weight battery packs, typically 12 V batteries, to ensure their safety. Design considerations include:
• Battery location and weight to maintain the weight distribution of the original vehicle.
• Component arrangement for accessibility.
• Battery boxes venting to prevent the buildup of hydrogen gases.
• The use of two contactors, an EVA standard. The primary contactor closes with the ignition switch; the secondary contactor closes with the accelerator pedal.
• No power cables inside the passenger compartment
Customers using our EV components in automobiles:
• Braintree Light (MA) - Saturn
• Bolton High School (CT) - Fiat X19
• Greenwich High School (CT) - VW Rabbit
• Jones Automotive (CT) - Escort
• Kolb & Company (VA) - VW Bug
• Noel Perrin (Book "Solo") - Audi 4000
• Northampton High School (VA)
• Reading Light (MA) - Geo Tracker
• Reed Technologies (OK) - Geo Metro
• Vermont Electric Car (VT) - Saab
MORE EV CONVERSIONS
LIGHT WEIGHT VEHICLES
EVA can assist you with light-weight vehicles, such as go-karts, motorcycles, riding lawn mowers, and more. The design typically uses 24-48 volt systems. These vehicles provide an opportunity for a high school or individual to become aware of EV technology at a reasonable cost. Customers include:
• Paul Anschel (PA)
• Central Connecticut College (CT)
• Darrell Murphy - Sundriver (TN)
• E-Tran (MN)
• Fran Mar Alternative Energy (NY)
• Ottawa Hills High School (MI)
• St. Mary's Central (WI)
• Zack Keele (CO)
ELECTRIC BOATS
EVA can assist you in designing an electric boat and providing components designed for the marine use:
• Albright contactors with a protected design. Only the terminals are exposed for connecting control and power wiring. Available for the main contactor as well as the F/R contactor.
• Marine throttle with F/R capability and neutral position. Designed for long life.
Customers include:
• Beckman Ltd. (RI)
• Clearwater Electric Boats Inc. (CT)
• Cummer Boat Company (FL)
• Seacure (RI)
MOTOR CONTROLLER SELECTION
Continuous Rating is important because it typically identifies the point of maximum efficiency. The following tables list the continuous horsepower for the most popular Advanced DC Motors and the current limit for the Curtis controllers.
Advanced DC Motors
Continuous Horsepower vs Voltage
Voltage
Motor 24 36 48 60 72 96 108 120 144
A89-4001 2 4 6 10 12
K91-4003 5 6 8 10
L91-4003 12 14
X91-4003 10 12 14 16 20
203-06-4001A 16 19 22 26
FB1-4001A 18 21 23 26 30
Peak Horsepower is 2-3 times the continuous rating and in most cases, the peak horsepower of the motor is limited by the controller. Therefore, to determine the peak horsepower for the controller, the following formula is used:
Horsepower = (Voltage x Amperage x Efficiency) / 746
Voltage
Controller 24 36 48 60 72 96 108 120 144
1204-001 275 275
1204-101 175 175
1204-401 275 275
1209B-6402 400 400 400
1221C-7401 400 400 400 400 400
1231C-7701 550 550 550 550 550
1231C-8601 500 500 500 500 500
The above motors and controllers are the most popular models. Other models are available. Curtis makes over 200 different controllers. This catalog provides an overview to help get you started.
COMMERCIAL CONDITIONS
SHIPPING
All items weighing less than 150 lbs are shipped by United Parcel Service (UPS). Heavier components will be shipped by motor freight.
WARRANTY
Most EV components have a one year replacement warranty. These warranties do not cover damage due to improper installation, abuse, disassembly of the component, or damage to other components or assemblies. The manufacturer determines the extent of the warranty and its applicability.
DISCLAIMER
Electric Vehicles of America, Inc. is not responsible for the installation, maintenance, use, or abuse of these components. The Purchaser is responsible for proper and safe installation, operation, and maintenance of components and the use of all tools used for that purchase. It is the Purchaser's responsibility to follow correct and proper conversion procedures for the specific vehicle and to adhere to safety precautions related to high voltage DC electrical systems. Therefore, the Purchaser agrees by placing the order and accepting delivery of the components from Electric Vehicles of America, Inc. that all components are used at the Purchaser's risk. The Purchaser will indemnify and hold Electric Vehicles of America, Inc., its stockholders, its employees, and its representatives free and harmless from all loss, liability, or damage resulting from any use of these components.
PRICES OF EVA COMPONENTS
Effective January 1, 1997
COMPONENT PRICE JOIN EVAmerica and get a discount!
Advanced DC Motors
A89-4001 $585
K91-4003 $630
L91-4003 $1020
X91-4003 $990
203-06-4001A $1395
FB1-4001A $1595
Scott Motor - For Electrathon racing
1 hp $260
Adaptor Plates (1/2" Thick)
Specific to your motor $150
Spacer (If required) $55
Motor Coupling $240
(Clutchless Design)
Clutch Design with Adaptor
Automobiles $625
Trucks $725
Balancing/Trim Flywheel $100
Curtis Controllers
1204-001 $305
1204-101 $270
1204-401 $355
1209B-6402 $670
1221C-7401 $760
1231C-7701 $1075
1231C-8601 $1075
Curtis Heat Sink (1231) $95
EVA Heat Sink/ Fan (12V) $40
Potboxes
PB-6 $70
PB-9 $70
FP-2 $175
Potentiometer (98191) $15
ET-103 $135
ET-Marine $135
Trojan Batteries* Let us calculate your specific needs.
T-105 (6V) $70
T-125 (6V) $80
T-145 (6V) $95
T-875 (8V) $102
SCS225 (12V) $85
* Pricing based on minimum of 10
DC/DC Converters
Curtis (24-36 V) $375
Curtis (48-60 V) $375
Curtis (72-96 V) $375
Curtis (120-144) $375
Albright Contactors - Other special contactors are available
SW-80 (On/Off 100A) $55
SW-80P (Protected) $65
DC-88 (Reversing 100A) $130
DC-88P (Protected) $140
SW-180 (On/Off 150A) $70
DC-182 (Reversing 150A) $185
SW-200 (On/Off 250A) $120
SW-202 (Reversing 250A) $300
Lester Chargers
Model 9800 (24V) $310
Model 6430 (36V) $340
Model 9695 (48V) $350
Model 9387 (96V) $720
Model 7740 (120V) $840
K&W Chargers
BC-20 (48-108V) $575 For 48-108V
LB-20 (requires BC-20) $175 For use to 120V
LB 120/144 (requires BC-20) $175 For use to 144V
BC-25 $750
Instrumentation
Voltmeter (Yokogawa) $55
Ammeter (Yokogawa) $55
Voltmeter (Specials Yokogawa) $55
Ammeter (Specials Yokogawa) $55
Voltmeter (Westberg) $55
Ammeter (Westberg) $55
Shunt $30
900R Fuel Gauge (36-96V) $135
900R Fuel Gauge (120V) $185
968 Fuel Gauge (72-168) $325
E-Meter with shunt & Filter $230
E-Meter Prescaler $70
E-Meter DC/DC Converter $85
Vacuum Equipment
Vacuum Pump $195
Vacuum Switch $105
Vacuum Gauge $15
Control Wiring (per foot)
This is cross-linked wire designed
to the highest standards.
16 Gauge $.20
14 Gauge $.30
12 Gauge $.40
10 Gauge $.60
Harness for Control Board
with disconnect $45 This harness includes control board wiring.
Power Cable & Lugs
1 Ga Cable - Black (ft) $2.00
2/0 cable - Black (ft) $2.50
2/0 cable - Red (ft) $3.00
Heavy Duty Lug $2.00
Round Automotive Lug $2.50
Heat Shrink w/ sealant $6/ft
Safety Components
Anderson Connectors (each half)
SBX-350 (2/0) $32
SB-50 (10 ga) $10
ANN Fuses (300, 400, 500) $25
First Inertia Switch $55
Buss Fuseholder $15
Fuseholder (4 Fuses) $6
In-Line Fuseholder $5
Electric Heater Package $170
MDO Board (2'x 4') $35
Neoprene Rubber (3 ft wide) $10/ft
Terminal Protective Covers $1.50
Vinyl hose (Clear) $1.50
Clamps for Vinyl hose $1.80
FOR TRUCKS
Motor Mount $120
S10/S15 Battery Boxes (4) $730
Truck Rear Pneumatic Lifts
with Hinge & Reinforcement$150
Tools
Quick Cutter 1 $23
Quick Cutter 2 $65
HexCrimp Tool $190 To assist you, we also rent this tool.
Quick Heat Gun $45
Books
"Build Your Own EV" $15
Curtis "Battery Book One" $5
"ZEV Activity Book" $3
EVA CUSTOMER SERVICES
EV Performance Calculations Free
EV Quotations Free
"Safety First" Paper Free
Safety First Video* Free
EV Conversion Guidelines* Free
This One Inch Notebook
Includes Schematics, Drawings, etc
* With Motor/Controller Purchase
EVAmerica Membership $30
Quarterly EVA newsletter
with $30 Discount Coupons
Tool Rental*
Industrial Crimper/Cutter $15/wk
Heat Gun $8/wk
* Deposit Required
Visa/ MasterCard/ Discover
This will expedite your shipment
Same day shipment in most cases.
Bob Batson (EVAmerica@aol.com)
Visit our Home Page at
http://www.inc.com/users/evainc.html
Electric Vehicles of America, Inc.
Tel# 508-897-9393
Fax# 508-897-6740
48 Acton Street
Maynard, MA 01754 USA
"EVA-Customer Service Is No. 1 "