Topeka Electric Motor’s first 100% electric vehicle project used a DC motor which is still the most common type of motor used in conversion projects. It was a learning process for us and ended up going through two distinct phases.

Our starting point for Phase One of the DC project was a 2000 Chevy S10 extended cab 3 door pickup truck. Phase One consisted of a Warp 9™ motor and LogiSystems controller. The battery pack was made up of ten 12 volt lead acid batteries. Additional features include two main 400 amp contactors, an inertia switch, on board water heat system, working five speed manual transmission, vacuum brakes, two battery chargers (one for the 120 volt battery pack and one for the 12 volt DC system), and a functioning alternator for the 12 volt DC system.The range for the original Phase One lead acid battery pack was over 40 miles. However, the lead acid battery pack was a disappointment because it lasted just over one year.

After much consideration, we decided to move beyond a lead acid battery pack, and Phase Two consists of a Lithium-Ion battery pack and some new equipment. The new battery pack is made up of 48 Hipower brand batteries. The new battery pack takes us up to approximately 165 volts with 200 amp hours per cell. The new battery pack required a new battery management system and a new charger. The battery management system is from REAP Systems Ltd. and we are using a Brusa charger. A new Soliton 1 controller was installed to handle the higher voltage and amperage. Our range is now up to 100+ miles. The truck has no difficulty achieving highway speeds of 75+ miles per hour. The truck is used on a daily basis for commuting and pick-up and delivery in our business.

Read the article featuring our DC electric truck in Topeka’s local newspaper on CJ Online. The article was picked up by the AP and appeared in a number of newspapers across Kansas. There was also a follow-up article describing the Phase Two changes.

Carl Clark of The Electric Car Company, Midvale, Utah, came and filmed the following video:

Summary of features/specifications:

• Functioning five speed manual transmission. It shifts just like it did when it was a gas powered vehicle. Many conversions are clutchless. We believe that a shiftable drive train offers many advantages. The drive train has a custom made adaptor to connect the motor to the transmission.
• Original 12 volts system was maintained with a functioning alternator for the lights, radio, etc.
• Phase One battery pack – ten J185H Trojan batteries 12 volts DC each – hooked in series.
• Phase Two battery pack – 48 Hipower Life PO4 Lithium-Ion Phosphate batteries, 3.2 VDC nominal voltage. Brusa charger NLG511-SX-130-260 VAC input. REAP Systems BMS with PC tool. Netbook computer to monitor the BMS. New Soliton 1 controller.
• Water heating system. Water passes through a heater core and warm air is delivered through the existing venting system.
• Two main contactors – 400 amp each.
• Inertia switch for added safety.

Topeka Electric Motor is an authorized dealer for NetGain Motors, Soliton Controllers and Hipower batteries. We have been selected to test prototype controllers.

Upon completion of our DC conversion project, we turned our attention to our AC conversion project. Return to the “Electric Vehicle” tab on the Home page and click on” AC Project” to learn about our full size half ton pickup truck that has been converted to 100% electric using a Baldor AC three phase induction motor.