DC Motor Controllers
Transcription
DC Motor Controllers
Welcome! Arizona PO Box W 885 Hampshire, A201 Jerome, AZ 86331 520 634-8445 520 639-0857 (fax) Washington 2023 East Sims Way, Suite W Port Townsend, WA 98368 360 385-5770 360 385-9295 (fax) Worldwide www.EVParts.com [email protected] Contents Well, its been quite a year. The 200 MPH barrier fell to EVs on the Bonneville Salt Flats not once, but several times. August saw the first ever electric vehicle drag race in Woodburn, Oregon, where Dennis Berube’s electric rail blew the doors off of a Dodge Viper. The event was put together by a bunch of enthusiasts, including Wilde EVolutions’ president Roderick Wilde, optimistically calling themselves NEDRA, the National Electric Drag Racing Association. Well, by the time you read this, NEDRA will most likely have been accepted by the NHRA as an authorized sanctioning body. EV racing will never be the same again. On the down side, we lost our partner, EV pioneer Ed Rannberg. Ed was a friend and inspiration as well as a business associate. We miss him constantly. And Lloyd Healey, another Bonneville campaigner, also passed away. Throughout it all, you’ve kept us busy supplying you with quality EV components. In response to your requests, you’ll find that this catalog contains 78 new products and 15 new vendors. And we’ve grown in other ways as well. Roderick and I have been joined by a third partner, Jacqueline Rickard. While Rod answers your tech questions and keeps the parts flowing, Jacqueline runs the office and makes sure everything gets done. This has left me with some time to consider how we can provide you with even better service. Our new toll free number is easier to remember ... just think EV Parts. And that’s now our web address as well. Please check out our web site periodically, as its our quickest way of getting new information to you. Welcome! ............................................................ 1 DC Motors ...................................................... 2 - 3 Motor Parts & Rebuilding Services ................... 4 Motor Mounts..................................................... 4 Motor-to-Transmission Adapters ................ 4 - 5 DC Motor Controllers ................................... 6 - 8 DC Contactors & Relays ................................ 8 - 9 Switches ............................................................ 10 Circuit Breakers & Fuses .................................. 11 Instrumentation ........................................ 12 - 13 Brakes ................................................................ 14 Heating .............................................................. 14 Battery Management ....................................... 14 Battery Chargers ............................................... 15 DC-DC Converters ........................................... 16 Wiring - cable ................................................... 16 Wiring - Terminals & Lugs ............................... 17 Wiring - Heat Shrink & Terminal Protectors .. 18 Wiring - Cable Clamps & Connectors ............. 19 Tools .................................................................. 20 Publications ............................................... 20 - 21 Clothing ............................................................ 22 How we do business ......................................... 23 Order Form ....................................................... 24 So let us hear from you. If we’ve done our homework, we’ll have what you need. But if we don’t, well, we need to start finding those new items for the next catalog! © Copyright 1998 Wilde EVolutions, Inc. All Rights Reserved Working on electric vehicles is potentially dangerous. Always read instructions and follow sound safety practices. Please call us if you have any questions. 1-888 Parts (888 387-2787) 1 DC Motors Series DC motors (where the field winding and armature are connected in series) are ideal for electric vehicle use because of their high torque, reasonable cost and the wide availability of efficient, cost-effective motor speed controllers. Motors are set up for counter-clockwise rotation during forward vehicle operation. If you are building or converting a car, such as a Honda, that needs the motor to rotate clockwise during forward vehicle operation, please let us know when you place your order. Because these motors can sustain serious damage if run beyond their designed RPM, we recommend use of an RPM limiter in applications where it is possible to run the motor with no load. Advanced D.C. We stock a wide variety of Advanced D.C. motors. The largest are commonly used for on-road electric cars and trucks, as well as 200+ MPH special purpose race cars. The smallest are used for lightweight vehicles such as go-karts, motorcycles, and ... furniture (try to visualize a couch and reclining chair motoring across the alkali flats of the Black Rock Desert in northern Nevada). General Electric Although slightly more expensive and not as widely used for EVs as the Advanced D.C. 9.1” motor, the GE 9” motor offers a real advantage when an application requires dual output shafts. Both shafts are the same diameter and have identical keyways. Kostov Kostov, Ltd. is a European manufacturer of DC motors, with sales in most European countries. They produce a wide range of motors, from 0.5 to 60 HP. The model KFG14402, rated 30 HP at 144 VDC, is a series wound motor with interpoles. It is a good choice for heavier EVs, or for use in high performance or regenerative braking applications. Horsepower and torque vary with voltage and current. Call us for HP and torque curves for the motor/controller/battery pack combination you are considering 2 Mfg. Part# 60036 4BB-02488 140-07-4001 140-01-4005 LEM-200 A89-4001 K91-4003 X91-4001 L91-4003 MTC-4001 203-06-4001 203-06-4001A FB-4001 FB-4001A 5BT1246B100 KFG-14402 12 24 24-36 24-48 12-60 36-72 48-96 72-144 72-120 96 72-120 72-120 72-144 72-144 72 - 144 144 na / 29 41 / 175 45 / 275 60 / 350 100/400 80 / 350 100 / 400 110 / 500 130 / 500 185 / na 178 / 550 178 / 550 190 / 600 190 / 600 184 / 750 192 / 600 Yes Yes No No Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes 15 00 25 00 35 00 45 00 Mfg. Revcor Scott ADC ADC LEMCO ADC ADC ADC ADC Prestolite ADC ADC ADC ADC GE Kostov 50 0 Part# 003-010 007-010 010-051 010-055 008-010 010-071 010-07K 010-07X 010-07L 009-070 010-080 010-081 010-090 010-091 012-091 011-010 Typical Vehicle Weight (lbs.) Continuous/ Intermittent Voltage Amps Reversible Price $ 47.50 260.00 376.00 525.00 1145.00 525.00 610.00 990.00 975.00 945.00 1365.00 1400.00 1550.00 1580.00 1725.00 1800.00 DC Motors Prestolite Although these motors are no longer made, they are still popular for specialized applications such as boat racing. We have remanufactured units in stock. The price includes your core in exchange. If you do not have a Prestolite motor to trade in, then there will be a core charge. Please call us for details. Scott This Scott permanent magnet motor is widely used for small, lightweight vehicles such as bicycles, scooters, and Electrathons. It comes with a removable base, and can also be face mounted. LEMCO The “pancake” design of the Lynch permanent magnet DC motor provides a power-to-weight ratio and efficiency unmatched by conventional small traction motors. It has been used in EVs ranging from go-karts and bicycles to on-road compact cars. This is the latest, second-generation design, which we import directly from The Lynch Electric Motor Company (LEMCO) in England. Revcor If you’re looking for a small, inexpensive, permanent magnet motor for a lightweight bicycle or similar project, this is a rear mount version of the motors used on the Zap bicycle. It was designed for powering cooling fans on large trucks, so its robust enough for continuous operation. Useful Formulas T = Torque NM = Newton Meters HP = Horse Power MPH = Miles Per Hour T = HP @ 5252 RPM WR = Wheel Radius RPM = Revolutions Per WR x RPM GR = Gear Ratio Minute MPH = —————— GR x 168 MPH x GR x 168 RPM = ———————— 1 Watt = 1 Amp @ 1 Volt WR At 100% efficiency 746 Watts = 1 HP WR x RPM GR = —————— MPH x 168 Figure 1000 Watts per HP, which is approximately 75% efficiency for 1 MPH = 1.47 Foot Per Sec all components in series. LBS FT = NM X .737 Part# 003-010 007-010 010-051 010-055 008-010 010-071 010-07K 010-07X 010-07L 009-070 010-080 010-081 010-090 010-091 012-091 011-010 1-888 Mfg. Mfg. Part# Revcor Scott ADC ADC LEMCO ADC ADC ADC ADC Prestolite ADC ADC ADC ADC GE Kostov 60036 4BB-02488 140-07-4001 140-01-4005 LEM-200 A89-4001 K91-4003 X91-4001 L91-4003 MTC-4001 203-06-4001 203-06-4001A FB-4001 FB-4001A 5BT1346B100 KFG-14402 Parts Weight 3.7 lbs. 17 lbs. 29 lbs. 38 lbs. 26 lbs. 50 lbs. 58 lbs. 82 lbs. 82 lbs. 105 lbs. 107 lbs. 107 lbs. 143 lbs. 143 lbs. 151 lbs. 176 lbs. (888 387-2787) D D A A E B C C A D E ------------------- Dimensions ----------------A B C D E F 3.98” 6.0” 5.5” 5.5” 8.07” 6.7” 6.7” 6.7” 6.7” 7.2” 8.0” 8.0” 9.13” 9.13” 9.0” 10.7” B B C F 2.98” 7.50” 8.27” 11.16” 5.39” 10.39” 11.34” 15.34” 15.34” 16.3” 14.69” 14.69” 15.62” 15.62” 17.75” 18.06” .48” 2.25” 2.12” 2.50” 1.18” 2.28” 2.28” 1.25” 1.25” .75” 1.37” 1.37” 2.00” 2.00” -.605” 1.04” .248” .625” .625” .875” .75” .875” .875” 1.125” 1.125” 1.125” 1.125” 1.125” 1.125” 1.125” 1.125” 1.375” 2.53” 1.98” 1.98” .875” .875” 2.10” .875” 2.10” .875” 1.25” 1.125” Mounting Rear Either Face Face Face Face Base Face Face Face Face Face Face Face Face Face 3 Motor Parts & Rebuilding Services Motor Rebuilding Parts for some OEM motors are no longer available. There are also instances where rebuilding an armature is less expensive than purchasing a new one. If you have a damaged motor and would like to know your rebuilding options, please call us. Brush leads Brush box Brush Motor Parts We offer replacement brushes and repair parts for Advanced DC, Prestolite, General Electric and Kostov motors. While we try to keep the most common items in stock, some components are special order. Please call us for availability and pricing. 010-B00 Stone for seating motor brushes 010-B01 High-performance 4-wire brush for most ADC motors $ 9.40 16.50 Advanced DC Motor Part Numbers Motor FB1-4001 Diameter 9.1" Brush A89-012A Spring B89-016 Brush box FAO-1064 Brush leads FAO-2034AS 203-06-4001 8" A89-012A B89-016 J89-1064 F95-2034JS L91-4003 6.7" A89-012A B89-016 J89-1064 B89-2034S X91-4001 6.7" A89-012A B89-016 J89-1064 B89-2034S K91-4003 6.7" B89-012A B89-016 A88-1164 B90-2034BS A89-4001 6.7" A89-012A B89-016 A88-1064 B90-2034BS 140-01-4005 5.5" 140-01-012A 140-01-016 140-01-1064 140-01-2034S 140-01-4001 5.5" 140-07-012A 140-07-016 140-07-1064 140-07-2034S Motor Mounts Full-Surround Motor Mount These full-surround mounts from EVCC securely grip the motor to resist twisting due to torque. They can also be moved to many locations along the motor to provide installation flexibility. 015-170 015-180 015-190 015-1K1 Motor clamp/mount for ADC 6.7” motors, 4.5 lbs. Motor clamp/mount for ADC 8” motors, 5.0 lbs. Motor clamp/mount for ADC 9.13” motors, 5.5 lbs. Motor clamp/mount for Kostov 10.7” motors, 6.0 lbs. $125.00 137.50 150.00 165.00 “Ell” Motor Mount Biscuit Motor Mounts This right angle motor mount provides small motor support in applications where the motor drives a belt or chain. It is predrilled for the following motors: These simple to use rubber shock mounts provide good vibration isolation and give your installation a clean and professional appearance. 2.9”D x 2.25”H, 10.9 oz. 010-051 010-055 010-071 ADC# 140-07-4001 ADC# 140-01-4005 ADC# A89-4001 The most common use for this mount is in go-kart construction. 6.0” L x 7.5”W x 8.25”H , 6.5 lbs. 015-200 Biscuit mount $12.50 each 015-160 “Ell” motor mount for ADC 5.5” or 6.7” motor $ 95.00 Motor-to-Transmission Adapters Motor Adapters With adapter sets available for over 100 different vehicles, EVCC has established itself as the leader in the field. If you don’t find your vehicle in the list on the next page, please call us about the steps necessary to design an adapter for your application. 015-070 015-080 015-090 015-0K1 4 Motor adapter for ADC 6.7” diameter motor Motor adapter for ADC 8” diameter motor Motor adapter for ADC 9.1” diameter motor Motor adapter for Kostov 10.7” diameter motor from $ 650.00 from 650.00 from 650.00 from 650.00 Motor-to-Transmission Adapters Make Alpha Romeo Alpha Romeo AMC AMC AMC BMW BMW BMW Buick Buick Buick Cadillac Chevrolet Chevrolet Chevrolet Chevrolet Chevrolet Chevrolet Chevrolet Chevrolet Chevrolet Chevrolet Chevrolet Chevrolet Chevrolet Chevrolet Chevrolet Chevrolet Datsun Datsun Datsun Dodge Dodge Dodge Dodge Dodge Fiat Ford Ford Ford Ford Ford Ford Ford Ford Ford Ford Ford Ford Geo GMC GMC Honda Honda Honda Honda Honda Hyundai 1-888 Model 2000 Sport Concord Gremlin Spirit 2002 320i 320i Skyhawk Skylark Somerset Cimarron Beretta Cavalier Celebrity Citation Citation Corsica Luv (pickup) S10 (pickup) S10 (pickup) S10 (pickup) S10 (pickup) S10 (pickup) S15 (pickup) Small block V8 Sprint Straight 6 240 Z 810 B2000 (pickup) D-50 (pickup) D-50 (pickup) Omni Omni Ram (mini van) Sypder 2000 Courier (pickup) Escort Fairmont Festiva Granada Mustang Pinto Ranger (pickup) Ranger (pickup) Ranger (pickup) Ranger (pickup) Taurus Metro Jimmy S15 (pickup) Civic Civic Civic CRX CRX Excel Parts Years 1982 - 1989 1982 - 1989 1978 - 1979 1977 - 1978 1979 1969 - 1976 1980 1982 1982 - 1987 1981 - 1987 1985 - 1987 1982 - 1988 1987 - 1989 1982 - 1989 1984 - 1988 1981 - 1982 1985 1987 - 1989 1979 - 1981 1981 - 1983 1984 - 1988 1983 - 1988 1984 1995 1984 All years 1988 All years 1972 - 1974 1977 - 1980 1974 - 1980 1982 - 1987 1988 1978 - 1983 1989 - 1990 1987 1976 - 1983 1976 - 1982 1986 - 1993 1978 - 1983 1988 - 1993 1981 - 1982 1979 - 1986 1975 - 1980 1983 - 1984 1988 - 1994 1988 - 1992 1986 - 1994 1986 1993 - 1995 1983 - 1988 1983 - 1988 1984 1986 1988 - 1989 1984 1988 - 1989 1994 Notes 4 cylinder 4 cylinder 6 cylinder 4WD automatic 6 cylinder 4WD automatic 4 cylinder 4 cylinder automatic 4 cylinder 4 cylinder 4 cylinder auto 6 cylinder 4 cylinder 4 cylinder 4 cylinder 4WD wagon (888 387-2787) Make Isuzu Isuzu Isuzu Jeep Land Rover Mazda Mazda Mazda Mazda Mazda Mercury Mercury Mercury Mercury Mercury Mercury Mercury MG Nissan Nissan Nissan Nissan Oldsmobile Oldsmobile Oldsmobile Oldsmobile Opel Plymouth Plymouth Plymouth Pontiac Pontiac Pontiac Pontiac Pontiac Porsche Saturn Toyota Toyota Toyota Toyota Toyota Toyota Triumph VW VW VW VW VW VW VW VW Volvo Volvo Volvo Model Years I-Mark 1988 - 1989 Impulse 1991 - 1993 Pup 1988 - 1993 Cherokee 1985 88 1971 B2000 (pickup) 1979 - 1984 B2200 (pickup) 1982 - 1984 B2300 (pickup) 1994 323 1986 - 1989 RX-7 1979 - 1983 Bobcat 1975 - 1980 Capri 1979 - 1986 Cougar 1981 Lynx 1986 - 1987 Tracer 1986 - 1989 Tracer 1989 - 1990 Tracer 1991 - 1993 MGB 1994-1/2 280Z 1977 - 1978 280ZX 1979 - 1983 Maxima 1977 - 1980 Pickup 1986 - 1989 Calais 1985 - 1987 Cutlass 1988 - 1989 Firenza 1982 - 1987 Omega 1981 - 1982 GT 1974 Horizon 1978 - 1983 Horizon 1989 - 1990 Neon 1995 2000 1982 - 1989 6000 1987 - 1988 Fiero 1984 - 1989 Phoenix 1981 - 1984 Sunbird 1982 - 1986 914 SC 1992 - 1994 MR-2 1985 - 1993 Paseo 1992 - 1993 Pickup 1972 - 1974 Pickup 1981 - 1985 Tacoma (pickup) 1996 Tercel 1985 - 1987 Spitfire All Bug All Golf/GTI All Jetta 1980 - 1984 Karmann Ghia All Micro Bus All Rabbit All Sirocco 1975 - 1984 Super Beetle All 240 1979 - 1982 260 1979 - 1982 850 1995 Notes gasoline 4 cylinder modified flywheel EX Turbo diesel 5 speed 7” motor only Specify tranny 5 DC Motor Controllers ON Pulse Width Modulation (PWM) DC motor controllers work by “pulsing” the current delivered to the motor. Much like a piston water pump, the individual pulses are smoothed to produce a continuous current flow. The motor sees an average of the “on” pulses (see graph at right). We stock a wide variety of motor speed controllers from several different manufacturers. Use the table below to quickly identify the make and model which best meets your needs. OFF Pack voltage Average motor voltage Time ON OFF Pack voltage Average motor voltage Time Auburn Scientific The Auburn Scientific controllers were designed specifically for high power DC applications. They have been extensively tested with the Advanced DC 9” motor. The controllers include both high pot input lockout and open pot shutdown, which reduce the possibility of unexpected controller operation. Low voltage shutoff and temperature controlled current reduction protect the controllers from damage. Although compatible with prior Auburn Scientific models, the new microprocessor versions offer switch activated low and medium power modes and activation of the main contactor once controller pre-charge cycle has completed. 020-160 020-161 020-162 020-163 Auburn Scientific PC600-144 “Kodiak” series, 55-144 VDC, 680 Amps, air cooled Auburn Scientific PWC600-144 “Kodiak” series, 55-144 VDC, 680 Amps, liquid cooled Auburn Scientific PWC600-192 “Grizzly,” 55-192 VDC, 680 Amps, liquid cooled Auburn Scientific PWC1200-192 “Grizzburger,” 55-192 VDC, 1200 Amps, liquid cooled Part# 020-160 020-161 020-162 020-163 Mfg. Auburn Auburn Auburn Auburn Mfg. Part# PC600-144 PWC600-144 PWC600-192 PWC 1200-192 Input Max Peak Voltage Current Power 55-144 680 90 kW 55-144 680 98 kW 55-192 680 131 kW 55-192 1200 230 kW 020-036 020-036R 020-072 020-011 020-012 020-014 Curtis Curtis Curtis Curtis Curtis Curtis 1204-001 1204-001 1209B-6402 1221C-7401 1231C-7701 1231C-8601 24-36 24-36 48-72 72-120 72-120 96-144 020-601 DCP DCP-1200 48-144 1200 173 kW 18 kHz air 020-401 EVCL Godzilla 120-300 1200 360 kW 15 kHz liquid 020-501 Sevcon SC 1218 020-208 020-208G 020-209 020-209G 020-212 020-212G Zapi Zapi Zapi Zapi Zapi Zapi H2 H2 H2 H2 H2 H2 Features: a Adjustable current limit c Contactor control f Integral fan r Rev limiting 6 R rg T w3 275 275 400 400 550 500 Switching Frequency 16 kHz 16 kHz 16 kHz 16 kHz 10 kW 15 kHz 10 kW 15 kHz 29 kW 15 kHz 48 kW 1.5 / 15 66 kW 1.5 / 15 72 kW 1.5 / 15 Cooling air liquid liquid liquid air air air air air air 24-36 180 6 kW 16 kHz air 80 80 96 96 120 120 400 400 500 500 600 600 32 kW 42 kW 48 kW 48 kW 72 kW 72 kW 18 kHz 18 kHz 18 kHz 18 kHz 18 kHz 18 kHz air air air air air air Rebuilt Regenerative braking Adjustable throttle response 90 day warranty $ 1425 1525 1875 3250 Features Length w3 17.75” w3 17.75” w3 17.75” w3 17.75” Width 7.0” 7.0” 7.0” 7.0” Height 4.25” 4.25” 4.25” 7.25” w12 R,w12 w12 w12 w12 w12 5.75” 5.75” 7.1” 7.1” 8.6” 8.6” 2.8” 4 lbs. 2.8” 4 lbs. 3.15” 8.8 lbs 3.15” 10.8 lbs 3.7” 15.5 lbs 3.7” 15.5 lbs 305 195 650 750 1095 1095 9.0” 7.5” 18 lbs. 2500 8.75” 5.0” 27 lbs. 5000 4.45” 2.76” 2.4 lbs 225 5.91” 9.50” 5.91” 9.50” 5.91” 9.50” 9 lbs. 17 lbs. 12 lbs. 23 lbs. 12 lbs. 23 lbs. 790 1182 937 1631 1120 1814 6.75” 6.75” 10.0” 12.0” 13.3” 13.3” a,c,f,r,t,w12 12.0” a,t,w31 16.0” 6.77” w12 rg,w12 w12 rg,w12 w12 rg,w12 10.79” 10.79” 13.58” 13.58” 13.58” 13.58” 3.35” 5.25” 3.35” 6.50” 3.35” 6.50” Weight Price 22 lbs. $ 1425 22 lbs. 1525 22 lbs. 1875 40 lbs. 3250 w31 90 day warranty for factory set voltages to 156V higher voltages for racing use only, no warranty w12 1 year warranty DC Motor Controllers Curtis PMC We stock a wide range of Curtis PMC controllers. The smaller models are suitable for material handling applications, golf cars, go-karts, scooters, bicycles and motorcycles; the larger models are used for on-road vehicles. All have infinitely variable throttle control, high pot input lockout, low voltage and high temperature current cutback. The “C” models use frequency shifting to reduce the operating frequency from 15 kHz to an audible 1.5 kHz when the PWM output is less than ~ 15%. Frequency shifting improves the current limit control and also helps protect the controller when the motor is in near-stall conditions. DCP The DCP-1200 controller provides high average currents at low throttle, providing exceptional acceleration, even in heavy vehicles. It features: • adjustable battery current limit (from 100 to 1200 Amps) • two-wire non-contact throttle position sensor, fail-safe, auto zero • adjustable rev limit with output to drive a standard 4 cylinder tachometer • air cooled - automatic integral fan, thermal overload protection • output to activate main battery contactor • three LED remote panel shows ON, Full Throttle & Thermal/Rev Limit • microprocessor based, dipswitch adjustable rev limit & throttle response 020-601 DCP-1200, 48-144 VDC, 1200 Amps $ 2500 EVCL The first feature listed by Electric Vehicle Components Limited for Godzilla is “Lots of power!” At 360 kW, it is the most powerful controller we stock. Its other features include: • liquid cooling for sustained high power operation • microprocessor control • programmable motor & battery current limits via RS-232 terminal • custom accelerator transfer function for smooth starts • smooth high-temperature cutback • low voltage protection 020-401 020-401C EVCL “Godzilla,” 120-300 VDC, 1200 Amps QTERM programming console $ 5000 250 Sevcon The Sevcon SC 1218 controller for permanent magnet motorss offers great realibility at low cost. It includes adjustments for neutral braking, plug braking, acceleration delay, current limit and accelerator input type. It is a great match for the Scott motor (#007-010). 020-501 Sevcon SC 1218, 24-36 VDC, 180 Amps $ 225 ZAPI If regenerative braking is important in your application, then the ZAPI H2 is an excellent choice. This type of electrical braking can reduce both the braking time and distance, and relieves stress and reduces wear on the mechanical braking system. This can be an important consideration with EVs, as their curb weight is often heavier than it was prior to conversion to electric power. 020-208 020-208G 020-209 020-209G 020-212 020-212G 020-2PC 020-2FP 1-888 Parts Zapi H2, 80 VDC, 400 Amps Zapi H2, 80 VDC, 400 Amps, with regen contactors Zapi H2, 96 VDC, 500 Amps Zapi H2, 96 VDC, 500 Amps, with regen contactors Zapi H2, 120 VDC, 600 Amps Zapi H2, 120 VDC, 600 Amps, rwith regen contactors Zapi H2 programming console Zapi footpedal assembly (888 387-2787) $ 790 1182 937 1631 1120 1814 375 129 7 DC Motor Controllers Heat sink Anodized aluminum heatsink for Curtis PMC 1221 and 1231 controllers. Will also fit Zapi H2 controllers by drilling four holes in heatsink. The machined fins provide increased surface area for heat dissipation. Air can be directed across the fins by either locating them in the airflow created by vehicle motion, or by using auxiliary fans. Use a dielectric grease between the controller and heatsink. 020-H10 Heatsink for Curtis PMC 1221 or 1231 controller $60.00 Stand-off spacers Throttle potentiometer All of our motor speed controllers use a throttle position input of 0-5 kOhms. These “pot boxes” house a potentiometer in a stainless steel housing. The spring loaded lever will conveniently attach to most vehicle throttle linkage. Where noted, a frame mounted micro-switch provides for control relays or other devices which need to be syncrhonized to throttle operation. These anodized aluminum spacers allow mounting a controller (with or without a heatsink) with the top of the controller or the fins of the heatsink facing the mounting surface. 020-H1S 3-3/4” stand-offs $ 4.00 each 020-PB5 020-PB6 020-PBP 020-TP0 Pre-charge resistor Aluminum housed wirewound resistor for controller pre-charging, 25W, 5 kOhms. 1.81”L x 1.09”W x 0.56”H, 0.5 oz. Curtis PMC #PB-5 pot box $ 55.00 Curtis PMC #PB-6 pot box, with microswitch 60.00 Replacement potentiometer for above 28.00 Thumb wheel pot for handlebar mounting 14.50 020-R01 Pre-charge resistor $ 4.95 025-G31 Fan guard, 3.15” x 3.15” 025-G41 Fan guard, 4.72” x 4.72” 025-A31 Fan, 115 VAC, 0.092 Amp, 33 CFM, 38 dBA, 3.15” x 3.15” x 1.5”, 14.1 oz. 025-D31 Fan, 12 VDC, 0.22 Amp, 42.5 CFM, 36.5 dBA, 3.15” x 3.15” x 1”, 4.4 oz. 025-D41 Fan, 12 VDC, 0.63 Amp, 120 CFM, 46.5 dBA, 4.72” x 4.72” x 1.5”, 11.4 oz. $ 2.45 2.95 22.00 19.50 19.50 Fans DC Contactors & Relays 12-48 VDC SPNO Contactors These small, lightweight, low voltage contactors work well in applications where size and weight are critical. The coil voltage for each model is the same as the rated contact voltage. The copper contacts are rated for 100 Amps continuous. Single pole, normally open. 2.56”L x 2.29”H x 3.19”W (including posts), 12.5 oz. 040-101 040-102 SPNO contactor, 12 VDC $ 14.50 SPNO contactor, 24 VDC 17.00 040-103 040-104 SPNO contactor, 36 VDC $ 19.00 SPNO contactor, 48 VDC 24.00 36-48 VDC SPNO Contactors These sealed contactors are designed for controlling battery-charging power circuits, low-voltage DC motor generator sets and golf carts. They have silver contacts and are dust and splash proof. The coil voltage is the same as the rated contact voltage. They have silver contacts and are rated for 200 Amps continuous. 3.69”L x 2.67” W x 2.95” H, 24 oz. 040-303 SPNO contactor, 36 VDC, 200 Amps $ 33.75 36-48 VDC SPDT Contactors These Single Pole Double Throw (SPDT) contactors can be wired together in pairs for reversing the direction of a serieswould DC motor (wiring diagram included). Like the SPNO contactors above, they have silver contacts. The normally closed (NC) contacts are rated at 100 Amps continuous; the normally open (NO) contacts are rated at 200 Amps continuous. The coil voltage for each model is the same as the rated contact voltage. 4.62”L x 2.67”W x 2.95”H, 27 oz. 040-313 SPDT, 36V, 100 Amps NC, 200 Amps NO $ 57.75 040-314 SPDT, 48V, 100 Amps NC, 200 Amps NO $ 57.75 48 VDC SPNO Contactor, 24 VDC Coil This lightweight on/off contactor is sealed against adverse environments such as water spray, airborne dust, etc. As such, it is ideal for exposed small motor applications such as go karts and electrathon vehicles. It has double breaking contacts with silver alloy contact tips, which are weld resistant, hard wearing and have excellent conductivity. Rated for 100 Amps continuous and 150 Amps intermittent use, the contactor will break 800 Amps at 48 VDC. 3.69”L x 1.92”W x 2.31”H, 14.9 oz. 041-080P-24 Curtis/Albright SW80P SPNO, 48 VDC, 100 Amps continuous, 150 Amps max, 24 VDC coil $ 54.95 8 DC Contactors & Relays Paired 96 VDC DPST Contactors For Motor Reversing, 12 VDC Coil Two lightweight double pole on/off contactors mounted on a common bracket together with inter-connecting electrical links for motor reversing. They have fast drop-out times (approx. 5 msecs.) and relatively slow pull-in times (approx. 20 msecs.). Motor direction changes can therefore be undertaken without risk of all contacts being closed at the same time. They are sealed for use in adverse environments such as water spray, airborne dust, etc. Rated for 100 Amps continuous and 150 Amps intermittent use, these contactors will break 800 Amps at 80 VDC. 3.69”L x 3.82”W x 2.31”H, 2.2 lbs. 041-822P Curtis/Albright SW822P Paired DPST, 96 VDC, 100 Amps continuous, 150 Amps max, 12 VDC coil $ 97.50 Paired 120 VDC DPST Contactors For Motor Reversing, 12 VDC Coil Two double pole on/off contactors mounted on a common bracket together with inter-connecting electrical links for motor reversing. There is a built-in failsafe so that if both coils are energized simultaneously, the contact design creates an open circuit. Rated fpr 250 Amps continuous and 450 Amps intermittent use, these contactors will break 1500 Amps at 96 VDC. 6.3”L x 3.26”W x 6.05”H, 7 lbs. 041-202 Curtis/Albright SW202 Paired DPST, 120 VDC, 250 Amps continuous, 450 Amps max, 12 VDC coil $ 320.00 96-120 VDC SPNO Contactors These Curtis/Albright contactors use silver cadmium oxide contact material, which is able to withstand burning and is extremely resistant to welding. Magnetic blowouts allow rupturing of high currents at high voltage. SW180 will handle upto 96 VDC, 150 Amps continuous, 225 Amps intermittent, and rupture 1000 Amps. SW200 will handle upto 120 VDC, 250 Amps continuous, 360 Amps intermittent and rupture 1500 Amps. 041-180 Curtis/Albright SW180 SPNO, 96 VDC, 150 Amps continuous, 225 Amps intermittent 041-200 Curtis/Albright SW200 SPNO, 120 VDC, 250 Amps continuous, 360 Amps intermittent $ 68.50 128.00 320 VDC SPNO Contactors Paired DPST SPDT SPDT SPNO These are the contactors to use when high currents are combined with high DC voltages. Kilovac relays are sealed, which insures that batteries can be disconnected quickly and safely with no external arcs. They are able to handle higher voltages and currents than any other contactor available for EVs today. In addition to EVs, Kilovac contactors are used in applications such as Space Station Freedom, the Commanche helicopter and the F-22 advanced fighter aircraft. Part# 040-101 040-102 040-103 040-104 040-203 040-303 041-080P-24 041-180 041-200 043-251 043-252 043-504 Mfg. Camdec UNI Camdec Camdec Club Car White-Rogers Curtis/Albright Curtis/Albright Curtis/Albright Kilovac Kilovac Kilovac Carry Mfg. Part# Voltage 98220-WR 12 UNI7-04 24 98520-WR 36 98626 48 8016 36 586-1171111 36 SW80P 48 SW180B 96 SW200 120 EV250-1A 320 EV250-2A 320 EV500-4A 320 040-313 040-314 041-201 White-Rogers White-Rogers Curtis/Albright 586-317111 586-320111 SW201 041-182 Curtis/Albright 041-822P 041-202 Curtis/Albright Curtis/Albright 1-888 Parts Amps 100 100 100 100 na 200 150 150 250 400 400 500 Coil Voltage 12 24 36 48 36 36 24 12 12 12 12 12 Length 2.56” 2.56” 2.56” 2.56” 3.09” 3.69” 3.69” 3.19” 4.00” 2.76” 3.03” 3.40” Width 3.19” 3.19” 3.19” 3.19” 2.13” 2.67” 1.92” 2.68” 3.23” 2.31” 2.34” 2.63” Height 2.29” 2.29” 2.29” 2.29” 2.88” 2.95” 2.31” 4.76” 5.92” 3.38” 4.06” 4.59” Weight 12.5 oz 12.5 oz 12.5 oz 12.5 oz 13.8 oz 24.0 oz 14.9 oz 1.5 lbs 3.0 lbs 1.5 lbs 1.8 lbs 3.3 lbs Price $ 14.50 17.00 19.00 24.00 18.00 33.75 54.95 68.50 128.00 350.00 425.00 495.00 36 48 120 200 200 250 36 48 12 4.62” 4.62” 4.0” 2.67” 2.67” 3.23” 2.95” 2.95” 5.92” 27.0 oz 27.0 oz 3.5 lbs 57.75 57.75 175.00 SW182B 96 150 12 5.04” 2.62” 4.76” 3.9 lbs 190.00 SW822P SW202 96 120 150 450 12 12 3.69” 6.3” 3.82” 3.26” 2.31” 6.05” 2.2 lbs 7.0 lbs 97.50 320.00 (888 387-2787) 9 Switches Inertia Switch An inertia switch trips on impact. These switches have COM, NC and NO connections, and are ideal for interrupting power to the main contactor in the event of an accident. This provides an extra margin of safety for both passengers and aid personnel. These inertia switches are manufactured by First Inertia for the Ford Motor Company. We remove them from vehicles which are no longer in service and then test them thoroughly before adding them to our inventory. 1.125”W x 1.75”D x 2.625”H, 2 oz. 045-500 Inertia switch (recycled) $ 30.00 Hella Switch This is an on-off switch with a removable key. Rating is 200 Amps continuous, 1000 Amps intermittent at 24 VDC. 2.25” dia. x 4.1”L with key engaged, 2.9”L without key, stem requires 0.88” dia. hole when switch is mounted behind panel, 5.1 oz. 046-020 Hella on-off switch with removable key $ 27.00 Pollak Switch Lever operated, sealed, battery disconnect switch. For 6 through 36 volts, 180 amps continuous, 1,000 amps peak. One piece die cast housing. 2.625”D x 4.125”L, 12.5 oz. Mounting stem is 0.75”D and 0.78”L. 046-030 Pollak SPST (on-off) switch, 6-36 VDC, 180 Amps continuous, 1000 Amps peak 046-030FP Face plate with on-off label, self adhesive mylar with black letters $ 27.25 1.50 Albright Switch This pull-on/push-off switch has been designed to provide a rapid means of isolating an EV battery pack in the event of a serious electrical fault. It has double breaking main contacts with silver alloy contact tips which are weld resistant, hard wearing and have excellent conductivity. Rating is 250 Amps continuous, 1000 Amps rupture @ 96 VDC. 2.45”W x 2.52”D x 4.5”H (4.95”H with contacts closed), 1.1 lbs. Options include an integral lock and an auxiliary microswitch. Once the contacts are closed, the key may be removed to allow the large knob to be used as a panic button. The auxilary microswitch contains botn normally open and normally closed contacts rated at 15 Amps @ 24 VDC. The auxilary contacts open in advance of the main contacts. 2.45”W x 2.52”D x 5.22”H (5.67”H with contacts closed), 1.3 lbs. Optional microswitch Optional lock 046-011 046-011AL Albright ED250 $ 95.00 Albright ED250 with optional lock and auxilary microswitch 115.50 EV Shifter Automotive style shifter with Forward, Neutral and Reverse positions. Positive locking in each position via handle mounted release lever. Illuminated position indicator. Each position has a switch rated for 10 Amps at 12 VDC. Shifter is factory tested to over 500,000 shifts. Face is 3”W x 6”L x 0.6”H, lever projects 5” from face, 5.7” clearance needed behind face, 2.5 lbs. Mounting holes behind face plate are 2” on center. Optional mounting flange allows attachment points to be 3.75” apart. Optional Mounting Flange 046-040 046-041 EV Shifter $ 225.00 Mounting flange (optional) 28.50 Time Delay Unit The TU150-1 single stage time delay unit is a solid state device which delays the operation of an electrical circuit for a preset period. The delay is adjustable between 0 and 5 seconds and can be wired independently of other delays or alternatively these delays can be wired in cascade so that it is necessary for the first delay to switch on before the following commences timing. Suppression is included in the delay circuit to prevent damage by voltage transients. Voltage range is 12-24 VDC, 2 Amps max. 2.6”L x 1.35”W x 0.8”H, 1 oz. 046-013 Albright TU150-1 Time Delay Unit $ 47.50 10 Circuit Breakers & Fuses 150A breaker with manual trip & manual reset Waterproof single pole thermal type 150 amp breaker for up to 30 VDC. 3000 amps interrupt. Has a manual trip push button. When breaker is tripped, the reset lever appears, giving a visual indication of the tripped condition. Operating temperature of -25° F to 180° F. 1/4-28 studs with rubber insulating boots. 2.875”L x 1.875”W x 1.75”H, 3.6 oz. 051-101 Circuit breaker, 30 VDC, 150 Amp, manual trip & manual reset $ 36.50 Mega Fuses and Holder Littelfuse brand Mega fuses, 100 to 250 amp 32 VDC rating. Bolt down design with color coded plastic body. Mounting holes are 0.34”D spaced 2.0” apart. 2.7”L x 0.75”W x 0.4”H, 0.6 oz. 051-210 100 Amp Mega fuse $ 5.90 Mega fuse holder. Convenient mounting for 051-212 125 Amp Mega fuse 5.90 051-215 150 Amp Mega fuse 5.90 Mega fuse. Black glass filled thermoplastic 051-217 175 Amp Mega fuse 5.90 construction with black cover for protection. 051-220 200 Amp Mega fuse 5.90 4.7”L x 1.6”W x 1.5”H, 3 oz. 051-222 225 Amp Mega fuse 5.90 051-200 Mega fuse holder $ 9.65 051-225 250 Amp Mega fuse 5.90 In-line fuse holder 32 volt, 30 amp maximum. Accepts 18 through 12 gauge wire. One piece molded construction rated for -40 to 150° C. Snap together nylon housings will fit 1/4” dia. round glass tube type by 7/8”, 1” or 1-1/4” long. 051-301 In-line fuse holder, crimp-on, snap together housing $ 0.95 Installation Auxiliary fuse panel This fuse panel is a convenient supplement to your vehicle's standard fuse system. It allows a safe, single point for addition of new auxiliary circuits. It uses standard ATO/ATC fuses or blade type circuit breakers. Each fused circuit has a 1/4" push-on terminal and is rated for 30 amps maximum. The input lead fits on a #10-32 stud. Maximum amperage for all circuits is 160. Recessed fuse contacts help to prevent shorting of circuits. 3.4”L x 2.3”W x 0.8”H, 1.9 oz. 051-300 Auxiliary fuse panel, six 30 Amp circuits $ 11.45 Safety fuses These fuses provide essential protection in the event of a short circuit in the high voltage system. In a vehicle with parallel battery stacks, there should also be a fuse between packs. These fuses may be mounted directly to other high voltage connections, such as shunts or battery terminals. Two distribution posts (part #084-150) may also be used for the 500 and 800 Amp fuses, so that the fuse is easily replacable. 050-020 050-040 050-050 050-080 Gould A13X200-4, 130V, 200A, 2.6”L x 1.1”D, 3.9 oz. $ 21.50 Gould A13X400-4, 130V, 400A, 2.6”L x 1.1”D, 3.9 oz. 21.50 Gould A25X500-4, 250V, 500A, 3.9”L x 1.5”D, 9.2 oz. 40.00 Gould A25X800-4, 250V, 800A, 3.9”L x 2.0”D, 17.1 oz. 46.50 Heinemann circuit breaker / manual disconnect The Heinemann circuit breaker requires very little pressure to trip. This provides a convenient method for installing a manual emergency disconnect without bringing high voltage cables into the passenger compartment. A simple pull cable or push lever may be used to remotely trip the breaker. 250 Amps continuous, 500 Amps for 22 seconds, 1000 Amps for 4 seconds. 10,000 Amps interrupt at 160 VDC. 7.13”L x 1.44”W x 5.5”H, 2 lbs. 051-140 Heinemann #GJ1-B3-DU0250-01C, 160 VDC $ 170.00 1-888 Parts (888 387-2787) 11 Instrumentation 055-040 055-010 055-020 Westach Gauges Nylon and glass construction make Westach automotive instruments the logical choice for accurate, corrosion-free instrumentation. Westberg Manufacturing has been dedicated to quality since it was founded in 1944. These gauges are built one at a time, by hand a6t the Westberg Manufacturing factory in Sonoma, California 055-030 All instruments have easy to read white lettering on a black background. Internal lighting provides good nightime visibility. The Speedometer and Tachometer are 3” diameter; all other gauges are 2” diameter. 055-010 055-020 055-027 055-029 055-030 055-031 055-032 055-042 055-043 055-040 055-041 055-050 055-051 055-052 055-MS1 055-MS2 Speedometer, 0-140 MPH $ 110.00 Tachometer, 0-7000 RPM (use with #055-651 sender) 149.00 Ammeter, 0-50 Amps (use with #055-613 shunt) 48.00 Ammeter, 0-250 Amps (use with #055-614 shunt) 48.00 Ammeter, 0-500 Amps (use with #055-610 shunt) 48.00 Ammeter, 0-1000 Amps (use with #055-611 shunt) 48.00 Ammeter, 0-1200 Amps (use with #055-612 shunt) 48.00 Voltmeter, 6-16 Volts DC 48.00 Voltmeter, 20-60 Volts DC 48.00 Voltmeter, 50-150 Volts DC 48.00 Voltmeter, 80-180 Volts DC 48.00 Controller Temperature, 100-260° F (use with #055-MS1 sender) 48.00 Motor Temperature, 100-400° F (use with #055-MS2 sender) 48.00 Motor Temperature, 100-700° F (use with #055-MS2 sender) 48.00 Temperature sender, attaches to controller 19.50 Temperature sender, imbeds in motor brush 19.50 055-042 055-051 055-052 Custom Gauges Deltec shunts We can also provide custom gauges with features such as: For use with E-Meter and ammeters shown on this and facing page. • programmable speedometer • chrome bezels • center pivot needles • multiple gauges in single housing • white on black, black on white, or custom colors These gauges are special order. Please call us for details. 12 055-613 055-614 055-610 055-611 055-612 Deltec MKA-50-50, 50 mv, 50 Amp $ 17.50 Deltec MKB-250-50, 50 mv, 250 Amp 21.75 Deltec MKB-500-50, 50 mv, 500 Amp 21.75 Deltec MKC-1000-50, 50 mv, 1000 Amp 41.75 Deltec MKC-1200-50, 50 mv, 1200 Amp 41.75 Instrumentation E-Meter Tach sender The E-Meter is a microprocessor based meter which provides the following functions in a compact 2" diameter package: • Amp-hours consumed • Battery pack state-of-charge • Kilowatt-hour consumption • Time of operation remaining at current consumption rate • Volts and Amps • Battery history • Optional RS-232 computer output 055-560 055-561 055-565 055-566 055-567 055-562 055-563 055-564 E-Meter, EV filter, 500 Amp $ 195.00 E-Meter, EV filter, 500 Amp, RS-232 interface 230.00 E-Meter, EV filter, 1000 Amp, shunt 299.95 E-Meter, EV filter, 1000 Amp, shunt, RS-232 interface 339.95 E-Meter pre-scaler, 0-100 Volt 62.50 E-Meter pre-scaler, 0-500 Volt 62.50 E-Meter DC-DC converter 34.95 E-Meter temperature sensor 49.95 This proximity sensor uses a hall effect pickup to sense motor RPM. Unlike sensors which use optical pickups, signal strength is not affected by dirt or dust. It is available with surface mount magnets which can be placed on a flywheel or other rotating surface. The output signal will drive most OEM and after market electronic tachometers, as well as the RPM limiter shown below. Housing is 0.4”D x 2.0”L, 1.8 oz., with 47” leads. 055-651 Tach sender $ 49.95 055-562 Magnet collar 055-563 This two piece nylon collar bolts easily onto the tailshaft of 7”, 8” and 9” Advanced D.C. motors. It is narrow enough to share the tailshaft with an auxilary equipment pulley. Two imbedded magnets work with the tach sender shown above. 2.75”D x 0.625”W, 1.2 oz. 055-564 055-652 Magnet collar, for use with Tach Sender shown above $ 35.00 Autometer RPM limiter The Auto Meter Pro-Control is a relay which is tripped when the input signal indicates motor RPM has reached a preset limit. The relay has both NO (normally open) and NC (normally closed) connections. RPM is set via a dial knob. A test button allows verifying proper operation at one half the dialed in RPM. When the RPM limit is reached, the relay is tripped for a fraction of a second and then reset. The relay can be used to break the input signal to a controller, making it appear that the driver’s foot has been lifted from the throttle. It can also be used to remove power from a high current contactor supply battery power to the controller. When used in this way, a latching relay is recommended so that power must be restored manually. This will prevent relay cycling which may cause repeated large current inrush into the controller. 055-701 Auto Meter Pro-Control RPM Limiter $ 149.95 ISSPRO RPM limiter Dual level speed switch. Lower switch point set to 6000 RPM, upper switch point to 7000 RPM. Can be used to break pot box signal at lower limit, and to remove power from main contactor at higher setting. Use with tach sender (#055-651) above. 5.25”L x 3.6”W x 1.75”H, 8 ozs. 055-710 ISSPRO RPM Limiter $ 135.00 “Fuel Level” meters A standard in the golf cart field, these inexpensive state of charge meters, can provide a visual indication of battery condition. 055-401 Fuel Level meter, 24 VDC nominal $ 25.00 055-402 Fuel Level meter, 36 VDC nominal 25.00 055-403 Fuel Level meter, 48 VDC nominal 25.00 1-888 Parts (888 387-2787) 13 Brakes Thomas Vacuum Pump Most passenger cars and trucks built in the last 40 years use vacuum assisted braking. If your EV was originally manuractured that way, then it is likely to be hazardous if their functionality is not maintained. This Thomas vacuum pump is both quiet and efficient. Its 12 VDC permanent magnet motor is rated at 1/10 HP. Vacuum performance is upto 22.9 in. Hg. We also include rubber shock mounts with threaded studs. 7.34”L x 4.25”W x 4.7”H, 4.5 lbs. 060-011 Thomas 12 VDC vacuum pump with shock mounts $ 175.00 Vacuum Switch This simple, lightweight vacuum switch turns pump on only when needed. Adjustable vacuum setting. Has COM, NC and NO connections. 2.25”L x 1.5”W x 1.5”H, 0.8 oz. 060-031 Vacuum switch $ 23.50 Heating Solid-State Heater Core This solid-state heating element can usually be used as a direct replacement for your vehicle’s original heater core. The temperature of the heater core is selflimiting at 180° F. The amount of heat produced is in proportion to the air flow across the element, so higher fan speeds will deliver more heat. The two-piece enclosure also allows use as a stand-alone heater. Core: 4.25”W x 4.75”H x 0.65”D, 7.2 oz. Enclosure: 4.9”W x 5.55”H x 2.5”D, 8.9 oz. 065-010 Solid-state heater core, 96-120 VDC, 1500 Watts $ 72.50 Battery Management BattProTM Equal Charge Battery Protector .875” Positive Negative When multiple sealed batteries are charged as a series string, it is unlikely that they will all receive a proper finish charge. The tendency is for some batteries to receive an insufficient charge while others are overcharged. This will not only reduce pack capacity and longevity, but can result in thermal runaway, where excessive heat buildup destroys the pack. 1.25” .625” Adjustment screw The BattProTM Equal Charge Battery Protector assures that all batteries in a series string are charged to the same finish voltage. As each battery reaches its preset charge voltage, current is shunted across the battery to prevent its becoming overcharged. This allows weaker batteries to reach full charge without stressing stronger batteries. 1.8 oz. 3.25” 072-010 BattProTM Equal Charge Battery Protector $ 19.95 Battery Terminal Protectors NOCO Terminal Protectors are felt rings, impregnated with NCP-2 Corrosion Preventative. This stops corrosion at the source - acid fumes escaping at the post due to imperfect seal, and in addition, actually improves connection at the battery post. 072-BTP Battery Terminal Protectors, can of 50 $ 14.95 14 Battery Chargers Zivan NG1 The Zivan NG1 battery charger is compact, rugged and simple to use. It makes an ideal onboard charger for smaller vehicles. A built-in fan assures cool operation and long life. 11.8"L x 6.3"W x 3.1"H, 4.9 lbs. 070-201 Zivan NG1, 110 VAC input, 12-72V output (specify voltage) $ 573.00 070-21T Zivan temperature compensation option 40.00 5.90 084-00G1 SB® 50 Series connector to match output DC connector Zivan NG3 If you have 220 VAC input and want a charger which provides a rapid charge with no need to worry about settings, then this industrial charger is an excellent choice. It is available in nominal voltages from 12 VDC through 192 VDC in 12 volt increments, plus 216 VDC. Charging rate runs from 100 Amps @ 12V to 10 Amps @ 216V. It is also available with 110 VAC input, with charging rates of approximately 70% of the 220 VAC models. The base is aluminum and the cover is ABS. There are two fans for cool operation. 16.7”L x 8.5”W x 3.5”H, 12.1 lbs. 070-222A 070-222B 070-223A 070-223B 070-224A 070-224B 070-21T 084-00G1 Zivan NG3, 110VAC input, 12-80VDC output (specify voltage) $ 829.00 Zivan NG3, 220VAC input, 12-80VDC output (specify voltage) 829.00 Zivan NG3, 110VAC input, 84-120VDC output (specify voltage) 849.00 Zivan NG3, 220VAC input, 84-120VDC output (specify voltage) 849.00 Zivan NG3, 110VAC input, 132-216VDC output (specify voltage) 879.00 Zivan NG3, 220VAC input, 132-216VDC output (specify voltage) 879.00 Zivan temperature compensation option 40.00 SB® 50 Series connector to match output DC connector 5.90 Russco 120 VAC Provides on-board charging of both flooded and sealed batteries. Constant current to 80% charge, constant voltage to finish, then timed shutoff. Both AC and DC rates are adjustable on front panel. Charges packs of 84 - 144 VDC nominal (>120 VDC require boost transformer). An optional battery temperature sensor will reduce charger output if the battery temperature rises to a reset level.10.25”L x 7.25”W x 6.4”H, 15.5 lbs. 070-510 Russco SC 18-120 SO, 110 VAC/20A input, 84-144 VDC output, 1800 watts $ 599.00 070-511 Russco SC 24-120 SO, 110 VAC/20A input, 84-144 VDC output, 2400 watts 675.00 070-512 Russco SC 30-120 SO, 110 VAC/30A input, 84-144 VDC output, 3000 watts 850.00 070-50T Battery temperature sensor option 40.00 070-50B Boost transformer for >120 VDC 115.00 Russco SC 50-240 SO For vehicles running 192 VDC nominal, this onboard charger provides the fast charging of 220 VAC input along with the convenience of charging at a reduced rate from 208 VAC or 110 VAC input. Both AC and DC rates are adjustable from the front panel. Charges at constant current to 80% charge, constant voltage to finish, and then timed shutoff for equalization. An optional battery temperature sensor will reduce charger output if the battery temperature rises to a reeset level. 070-520 110/208/220 VAC input, 192 VDC output 070-50T Battery temperature sensor option $ 995.00 40.00 Lester chargers Long the standard of the golf cart industry, these offboard chargers for flooded-cell batteries are extremely reliable. They are often used around the clock where utility vehicles are charged in shifts. Models are available for output voltages from 12 to 120 VDC nominal. Inputs available are 115 VAC and 230 VAC, with some models accepting either input. Prices range from $190.00 to $968.00. Please call for information on the models suitable for your application. Charger interlock relay This relay is triggered by 110VAC and breaks or completes a 12VDC circuit. For chargers which do not have builtin safety interlocks, this provides a means of disabling an EVs drive system while the vehicle is being charge. This prevents accidently moving the vehicle with the charger connected to the AC power source. 045-230 NTE #R14-11A10-120, DPDT, 10 Amps @ 28 VDC, 120 VAC coil 045-240 NTE #R95-110 socket for above 1-888 Parts (888 387-2787) $ 11.00 9.50 15 DC-DC Converters A DC-DC converters provides 12 VDC power for auxiliary uses from the main battery pack. This gives you the equivalent of a very large 12 volt battery which doesn’t quickly fade under a full load of lights, heater fan, wihdshield wipers, etc. The DC-DC converter should be sized to match your 12 VDC load. An auxiliary battery should also be used in parallel with the DC-DC converter output, both for safety (in case the DC-DC converter fails), and to even out intermittent loads such as turn signals and brake lights. Todd DC-DC converters Todd not only produces a full line of DC-DC converters, but backs them with a great warranty. If you should find that your unit needs repair, they provide a rapid turnaround service to get you back on the road quickly. 075-02L PC-20LV, 96-120 VDC input, 20 Amps out $ 225.00 075-04L PC-40LV, 96-120 VDC input, 40 Amps out 290.00 075-030 PC-30, 140-180 VDC input, 30 Amps out 175.00 075-040 PC-40, 140-180 VDC input, 40 Amps out 235.00 075-03H PC-30HVC, 144-192 VDC input, 30 Amps out 190.00 075-04H PC-40HVC, 144-192 VDC input, 40 Amps out 245.00 075-05H PC-45HVC, 144-192 VDC input, 45 Amps out 270.00 Vicor DC-DC converter This extremely small, lightweight, high density converter is ideal for applications where size and weight are important, and current needs are minimal. Typical applications are motorcycles and race cars. Rated for a nominal input voltage of 110 VDC, this unit has an operating range of 66 to 160 VDC. Output is 12 VDC at 100 Watts. 2.58”L x 2.5”W x 0.62”H, 4.5 oz. 075-101 Vicor MegaMod Jr, 110 VDC nominal in (66-160 VDC max), 8.3 Amps @ 12 VDC out $ 185.00 Vicor DC-DC converter heatsink Heatsink for use with above DC-DC converter provides realibility by keeping converter cool. Fins are 0.9” high. 075-101H Vicor MegaMod Jr Heatsink $ 10.00 Wiring - cable Welding Cable Welding cable is made with very fine copper wire and insulated with a synthetic rubber. It is more flexible than battery cables, especially in cold temperatures. Welding cable is easier to route in tight spaces. 080-06B 080-04B 080-10B 080-20B 080-20R 16 6 ga. welding cable, black, per foot 4 ga. welding cable, black, per foot 1/0 welding cable, black, per foot 2/0 welding cable, black, per foot 2/0 welding cable, red, per foot $ .90 1.20 2.35 2.80 3.40 Wiring - Terminals & Lugs Die Cast Copper Crimp Terminals Electric vehicle wiring must handle high currents at high voltages in a less than ideal environment. A failure of wiring components has the potential to cause severe vehicle damage and/or serious personal injury. We recommend using top quality components and following the manufacturers recommendations for crimping and sealing. All of the lugs and terminals we offer are manufactured by QuickCable, and have the following characteristics: • Made of die-cast copper alloy, tin plated to resist corrosion • Tin plated twice as thick as industry standards • All clamps include tin plated 5/16" battery bolts and shoulder nuts • Terminals are imprinted with die codes for all major crimping tools • Within a wire size, all terminals share the same crimp die settings • Made in U.S.A. • Patented Copper alloy for Smooth yoke for Same strip length Crimp die Clamps and lugs Gauge and polarity Terminals for automotive style posts Uniform wall Tin plated for Longer barrels permit straight right left Original MagnaLugs® flag 081-04SP 4 ga. battery terminal - straight, positive $ 2.80 081-04SN 4 ga. battery terminal - straight, negative 2.80 081-1SP 081-1SN 1/0 battery terminal - straight, positive 1/0 battery terminal - straight, negative 2.90 2.90 081-2SP 081-2SN 081-2RP 081-2RN 081-2LP 081-2LN 081-2FP 081-2FN 2/0 battery terminal - straight, positive 2/0 battery terminal - straight, negative 2/0 battery terminal - right elbow, positive 2/0 battery terminal - right elbow, negative 2/0 battery terminal - left elbow, positive 2/0 battery terminal - left elbow, negative 2/0 battery terminal - flag, positive 2/0 battery terminal - flag, negative 2.90 2.90 3.10 3.10 3.10 3.10 3.95 3.95 left 082-23L straight 45° 082-234 right 082-23R 90° 082-239 1-888 Parts (888 387-2787) MagnaLugs are superior to standard tube lugs in five important ways: • Wider pads for better electrical contact • Thicker pads for greater strength • 80% thicker walls for greater conductivity and strength • MagnaLugs use same crimp settings as battery clamps, saving you time, trouble and errors • MagnaLugs exceed SAE conductivity standards Made of 100% copper, tin plated twice as thick as industry standards. Can be crimped or soldered 082-064S 6 ga. battery lug - 1/4” hole, straight 082-065S 6 ga. battery lug - 5/16” hole, straight $ .95 .95 082-044S 4 ga. battery lug - 1/4” hole, straight 082-045S 4 ga. battery lug - 5/16” hole, straight 082-043S 4 ga. battery lug - 3/8” hole, straight 1.15 1.15 1.15 082-14S 082-15S 082-13S 1/0 battery lug - 1/4” hole, straight 1/0 battery lug - 5/16” hole, straight 1/0 battery lug - 3/8” hole, straight 1.60 1.60 1.60 082-24S 082-25S 082-23S 082-22S 2/0 battery lug - 1/4” hole, straight 2/0 battery lug - 5/16” hole, straight 2/0 battery lug - 3/8” hole, straight 2/0 battery lug - 1/2” hole, straight 1.75 1.75 1.75 1.75 082-45S 082-43S 082-42S 4/0 battery lug - 5/16” hold, straight 4/0 battery lug - 3/8” hole, straight 4/0 battery lug - 1/2” hole, straight 2.55 2.55 2.55 082-234 082-239 2/0 battery lug - 3/8” hole, 45° 2/0 battery lug - 3/8” hole, 90° 1.95 1.95 082-23L 082-23R 2/0 battery lug - 3/8” hole, left elbow 2.35 2/0 battery lug - 3/8” hole, right elbow 2.35 17 Wiring - Heat Shrink & Terminal Protectors Heat shrink tube Using heat shrink tube will extend the life of your cables and give you more dependable service • Protects against corrosion • Identifies positive & negative polarity • Acts as strain relief & prevents abrasion 083-01B 1-1/2” heatshrink for above battery terminals & lugs, meltable sealant, black 083-01R 1-1/2” heatshrink for above battery terminals & lugs, meltable sealant, red $ .50 .50 Battery Terminal Protectors • Protects your electrical system from shorts, which can be extremely dangerous at the voltages used in most EVs • Reduces the chance of sparks and battery explosions • Reduces battery terminal corrosion • Color coded for easy polarity identification • Made from high temperature polyvinal chloride rated at 190° F, 90° C • All fit either 1/0 or 2/0 cable 083-21B Boot, lug & stud, black 083-21R Boot, lug & stud, red $ 1.25 1.25 083-22B Boot, heavy duty lug & stud, black 1.35 083-22R Boot, heavy duty lug & stud, red 1.35 083-21 083-22 083-23 083-23B Boot, tab style, black 083-23R Boot, tab style, red 1.80 1.80 straight right left 18 083-1SB Boot, straight terminal, black 083-1SR Boot, straight terminal, red $ .80 .80 083-1RB Boot, right elbow terminal, black 083-1RR Boot, right elbow terminal, red 2.30 2.30 083-1LB Boot, left elbow terminal, black 083-1LR Boot, left elbow terminal, red 2.30 2.30 083-1FB Boot, flag terminal, black 083-1FR Boot, flag terminal, red 2.30 2.30 flag Wiring - Cable Clamps & Connectors Cable T-Clamps These ingenious T-Clamps hold battery cables away from your frame or sheet metal to elimate problems from vibration and chafing. Manufactured from 6-6 Zytel nylon, T-Clamps are nonconductive, unaffected by automotive fluids, and will not melt, distort, fade, stain or discolor under normal use. Engineered to "pre-load," T-Clamps hold cable securely and work as their own lock washer with self-locating pegs for ease of installation. All T-Clamps come with stainless steel 10/32 hardware. Lifetime warranty. 083-451 Single place T-Clamp, 5/8”, black 083-492 Double place T-Clamp, 9/16”, black 083-452 Double place T-Clamp, 5/8”, black $ 2.90 3.90 3.90 Anderson connectors ® ® The standard of the industry for many years, the Anderson SB Series and Powerpole connectors provide a quick disconnect for chargers, controllers and other EV components. Housings mate together, with two connectors of the same color functioning as a plug and receptacle. The SB® Series are available in three sizes with amperage ratings of 50, 175 and 350 Amps in a two pole design, 600 volts maximum. We carry the 175 and 350 amp units in three colors. UL listed as a recognized component. Each SB® series connecter includes two crimp on contacts for the indicated wire size. Powerpole® housings are available for 50 Amps, 600 volts maximum, in two colors. The housings do not include contacts, which are listed separately. NOTE: Part numbers are for single connectors - you must order two to have a connecting pair. Different color connectors will not plug together. 084-00G1 SB® 50 Series connector, for 10-12 gauge wire, with contacts, gray 084-00G SB® 50 Series connector, for 6 gauge wire, with contacts, gray $ 5.90 5.90 084-01B 084-01G 084-01R 084-01C SB® SB® SB® SB® 175 Series connector, for 1/0 gauge wire, with contacts, blue 175 Series connector, for 1/0 gauge wire, with contacts, gray 175 Series connector, for 1/0 gauge wire, with contacts, red 175 Series crimp on contact, for 1/0 gauge wire 12.60 12.60 12.60 2.80 084-02B 084-02G 084-02R 084-02C SB® SB® SB® SB® 350 Series connector, for 2/0 gauge wire, with contacts, blue 350 Series connector, for 2/0 gauge wire, with contacts, gray 350 Series connector, for 2/0 gauge wire, with contacts, red 350 Series crimp on contact, for 2/0 gauge wire 24.50 24.50 24.50 4.80 084-03B Powerpole® housing, for 6 gauge wire, black 1.53 1.53 084-03R Powerpole® housing, for 6 gauge wire, red 084-03C Powerpole® crimp on contact, for 6 gauge wire (also fits SB® 50 Series) 1.14 Locking half Mounting half Manual release Insulated non-corrosive steel structure. Provides smooth and efficient power connection/disconnection. Maintains connector alignment. 084-01L 084-01M 084-02L 084-02M 1-888 Locking half for SB® 175 Series $ 21.00 Mounting half for SB® 175 Series 9.00 Locking half for SB® 350 Series 21.00 Mounting half for SB® 350 Series 9.00 Parts (888 387-2787) Distribution post Sometimes you need another place to mount something ... a fuse, those cables from two parallel battery stacks. These distribution posts are the answer. They have a bronzed 3/8” bolt in a non-conducting base. They’re just the right size for our 500 Amp and larger fuses and 3/8” cable lugs. 084-150 Distribution post, 3/8” $ 8.95 19 Tools QuickCutter QuickStrip • Cuts cable up to 2/0 • Only 9" long, fits any tool box • Insulated grips • Strips up to 4/0 Ga. cable • Only 51/2" long • Includes spare blade 085-010 QuickCutter $ 18.85 085-020 QuickStrip $16.95 Brute Terminal Crimper • Inexpensive, simple, crimping tool • Use with hammer, or vise • Crimps 8 Ga. - 4/0 Ga. terminals • Spring loaded pin locks in 'up' position for loading terminal and cable. Pin is then released to hold terminal securely during crimping, a Quick-Cable exclusive. 085-030 Brute Crimper $23.75 OuickHeat HexCrimp • Designed for heavy duty battery terminals • Crimps terminals 8 Ga. - 250MCM (6/0 Ga.) • Adjustable crimp dies permanently attached • Die settings have letter, number, and color codes • Crimps all major brands of battery terminals, copper lugs, and splices • Insulated grips for comfort and safety 085-031 Hex Crimper $ 179.50 • commercial grade heat gun with shrink tube deflector. Dual temperatures, 750° or 1000° F, durable high impact plastic housing. Stands for hands-free operation. 120 volts, 1200 watts, UL and CSA approved. 085-040 Quick Heat gun $ 40.75 Publications Here are a variety of books related to EVs. We’re always looking for new titles, so be sure to ask us about any we’ve added since this catalog was published. We’re also reviewing EV video tapes, particulary “how-to” overviews, so call us or check out our web site to see what we’ve found. Build Your Own Electric Vehicle by Bob Brant 1st Edition Paperback, 310 pages Published by Tab Books Publication date: November 1995 ISBN: 0830642315 100-010 $ 19.95 This is probably the most comprehensive guide to the components and systems used by electric vehicles. The author begins with a historical perspective, provides the theory behind the components used in EVS, and concludes with a description of the conversion of a Ford Ranger pickup. Convert It! by Michael Brown 3rd Edition Paperback, 128 pages Published by Future Books Publication date: November 1993 ISBN: 1979857944 100-011 $ 24.95 20 Michael Brown is a professional auto mechanic who became involved in electric vehicles when one of his customers asked him to convert a car to electric power. This step-by-step guide for converting an internal combustion vehicle to electric power draws on the author’s many years of performing conversions. From Gasoline to Electric Power: A Conversion Experience by Gary Powers 1st Edition Paperback, 118 pages Published by Longbarn Press Publication date: 1997 ISBN: 0966095308 100-012 $ 9.95 This is the story of a do-it-yourself conversion project. Author Gary Powers began with no knowledge of EVs and limited experience of automobile maintenance. He takes you through his conversion of a 1986 Chevrolet S-10 pickup over a 15 month period. Publications The New Electric Vehicles: A Clean & Quiet Revolution by Michael A. Hackleman Paperback, 272 pages Published by Home Power Publication date: April 1996 ISBN: 0962958875 Hackleman provides an eclectic mix of EV philosophy, howto and profiles of vehicles and individuals involved with EVs. In addition to on-road EVs, he includes descriptions of everything from electric tractors and utility vehicles to electric aircraft. A fun book that will certainly spur your imagination. The Car That Could: The Inside Story of GM’s Revolutionary Electric Vehicle by Michael Shnayerson Hardcover, 295 pages Published by Random House Publication date: September 1996 ISBN: 067942105X Although written with the electric fork lift truck user in mind, much of the information in this book applies to batteries in general and will be helpful to anyone interested in learning about them. It shows how to minimize energy costs by correctly selecting batteries, properly charging them, and avoiding damage through over-discharge. There are explanations of efficiency, Ohm’s law, current and amperes, the Volt, the Watt, the KilowattHour, the Ampere-Hour, battery capacity and end point voltage (final charge voltage). It also provides a description of how lead acid batteries are made and how they work. Wiring 12 Volts for Ample Power by David Smead Paperback Published by Rides Publishing Company Publication date: November 1990 ISBN: 0945415036 100-041 $24.95 “Allowed complete access to GM’s top-secred electric-car project, Shnayerson tells the story of the assorted BP’s and engineers as if this were a thriller. Shnayerson’s explanations of the technical terms are clear and concise, and his understanding of the machinations of the GM behemoth is remarkable. Fun and beautifylly written ... this business adventure story has heroes, a villan or two, and genuine hope for the future. A masterful job.” --- Kirkus Reviews Taking Charge: The Electric Automobile in America by Michael Brian Schiffer, Tamara C. Butts, Kimberly K. Grimm Hardcover Published by Smithsonian Institute Press Publication date: September 1994 ISBN: 1560983558 100-042 $ 24.95 The early history of electric automobiles was from 18951920. Schiffer describes the cars of that period and why they were supplanted by gas engined cars. The quieter and safer electric cars were preferred by women, but men were drawn to the speed and performance offered by the gasoline engine. The book includes many vintage EV photos. Parts by the staff of Curtis Instruments, Inc. Paperback, 72 pages Published by Curtis Instruments, Inc. Publication date: 1981, third printing 1994 ISBN: 0939488000 100-030 $ 4.95 100-040 $ 24.95 1-888 Battery Book One (888 387-2787) 100-031 $ 19.95 This book has become a best seller for boat owners, where 12 volt systems must operate well in corrosive conditions, often far from land and repair facilities or replacment parts. It presents general schematics, wiring details and troubleshooting information. One chapter is devoted specifically to many of the electrical wiring diagrams necessary for a modern small boat. Complete Premarital Contracting: Loving Communication For Today’s Couples by Jacqueline Rickard Paperback, 225 pages Published by M. Evans and Company Publication date: 1993 ISBN: 0871317397 100-020 $ 12.95 Wilde EVolutions’ own Jacqueline Rickard has produced a book which will prove invaluable to the EV enthusiast who must balance the many hours which an EV conversion can consume with a normal life. Using the point at which two individuals are making the committment to become a couple, she presents the communication tools with which issues can be clarified and conflicts resolved, all in a manner which strengthens trust and enhances intimacy. A valuable book for couples of all ages. 21 Clothing Wilde EVolutions baseball cap Keep the sun out of your eyes with this stylish embroidered cap. Has the distinctive Wilde EVolutions name and logo abrove the brim. 120-100 Baseball cap, specify black or khaki $ 12.00 Maniac Mazda Drawn by well known street rod artist Dave Bell, aka Henry Hirise, the Wilde EVolutions’ RX-7 is shown breaking the 100 MPH speed limit in the Arizona Desert, with driver Roderick Wilde’s ponytail blowing in the breeze. 120-011 Maniac Mazda t-shirt, specify S, M, L, XL $ 15.00 Lighting Rod II Our famous ‘29 Ford Roadster electric street rod is drawn in all its yellow glory on this bright red shirt. You’ll definitely get attention with this one. 120-010 Lighting Rod II t-shirt, specify S, M, L, XL $ 15.00 Look Ma ... No Tailpipe! This white pocket tee simply says “It’s Electric!” above the front pocket. But the back makes the point more dramatically. The smiling driver of this jaunty red roadster is pointing out one of the advantages of driving electric. 120-012 Look Ma ... No Tailpipe!, specify M, L, XL $ 16.00 22 How we do business You Have A Friend In The Business Product Guarantee Wilde EVolutions wants to be your source for electric vehicle components. We stock hundreds of items and most orders are filled and on their way within 24 hours. With your satisfaction guaranteed, we will cheerfully make adjustments, refunds or credit your account on standard catalog items during the first 30 days after delivery. If a product proves to be defective, it will be repaired or replaced immediately. We must be notifed of any product defect with 90 days following ship date. It's easy to order from Wilde EVolutions, just call, write, fax, or send us email, and your order will be quickly shipped out. Wilde EVolutions is committed to customer satisfaction with prompt delivery and quality products. Give us a try today, you won't be disappointed. Easy Ordering Mail, call, fax, or email your order. Normal business hours are from 9:00 to 5:00 Pacific Time. After hours, your call will be recorded and we will promptly return your call the next business day. Prices Liability There are no expressed or implied warranties. Since seller cannot control the manner or use of its products after the sale, the seller will not be responsible for any consequential or indirect damages. Stop By If You’re In the Neighborhood We’re always happy to have customers drop in, but its a good idea to call first, as we migrate twice a year. Winter finds us in the former mining town of Jerome, Arizona Port Townsend, (population 450). Summers we’re in the beautiful Washington old Victorian seaport town of Port Townsend, Washington (population 7500). Migration Route Prices are subject to change without notice. Our prices do not include freight or any federal, state or local taxes. State sales tax will be added to all items delivered in Arizona or Washington. Terms All prices shown or quoted are FOB point of shipment. We accept Visa, MasterCard, Novus/Discover and American Express, money orders and business or personal checks. Shipments can also be sent COD to addresses within the United States and Puerto Rico. Shipping For shipments to destinations within the United States, Puerto Rico and Canada, we ship by UPS for items under 150 lbs., and by common carrier for heavier items. International shipments are typically sent via air freight. Same day shipment is generally available on most items. Air freight and other premium freight services are also available. Although all shipments are insured, they are sent FOB point of shipment. Please inspect all shipments and report any shortages or damage to the delivering carrier immediately. 1-888 Parts (888 387-2787) Jerome, Arizona A Winning Team Show below is our wining 1996 APS Electrics team. From left to right: Anne Baumann, Gary DeWeese, Carl Baumann, Jacqueline Rickard, Bob Rickard, Tony Cygan (crew chief), Abby Wilde, Roderick Wilde (driver), Robert Witkoff, Shannon Cash. photo by Kitty Rodden 23 Order Form 98-10 Mail Wilde EVolutions, Inc. P.O. Box W Jerome, AZ 86331 Phone Toll Free 888 EV Parts 888 387-2787 24 Hour Fax 360 385-9295 or 520 639-0857 Ship to: Bill to: Customer Name P.O. # Company Customer Name Shipping Address Company City Phone ( State ) Zip Fax ( Internet [email protected] http://www.EVParts.com Address ) City State Zip Notes: Payment Method: ❏ Open Account * ❏ Visa ❏ COD ❏ MasterCard Card number: Quantity Shipping Information: ❏ Check ❏ Discover ❏ American Express __ __ __ __ - __ __ __ __ - __ __ __ __ - __ __ __ __ Wilde EVolutions Part Number * Call for details on opening an account. 24 ❏ Credit Card: Ship Via: Expiration __ __ Mo. Description Card holder signature: __ __ Yr. Price Shipping charges are additional and added to order Amount