Due to the electric converison the original driveshaft can’t be used. It has a bracket that attaches to the original engine. So I had to find out which one would fit my Elise. A visit to a workshop where they had the PG Elektrus in for repair solved my problem.
PG Elektrus by Michael Fröhlich
The PG Elektrus is based on the Lotus Club Racer.
The drive shaft in the PG Elektrus still had the label with partnumber on it. It showed B120D4004F which is correct for an Elise CR. I now know why the drive shafton my car failed, it is designed to cope with 136 BHP and 160Nm (118lb ft) instead of the 200 BHP and 225Nm (165 lb ft) of the AC-150.
Driveshaft drawing A120D4004F
I 0rdered the drive shaft en found out that my car had an early model A120D4004F drive shaft. the new one B120D4004F has different CV joints.
Last night I hit a speed bump and broke the RH driveshaft, i was putting my foot down quite hard in second gear. The back wheels did spin a little.
I stranded 500m from my home
My wife was so nice to tow me home.
I asked the dealer which driveshaft would fit my Elise, they quoted the original driveshaft for an 2009 111R at €946,- with partnumber A120D0018F (#2).
Driveshaft drawing A120D0018F
Due to the electric converison the original driveshaft can’t be used. It has a bracket (#11) that is attaches to the original engine. So I had to find out which one would fit my Elise.
After the engine was pulled and the clutch assembly had been removed from the adapter plate the Pertinax isolation was visible.
The isolation aroud the boults where the cause of the charge error.
Fly wheel bolds
I made some Nylon isolators
New Nylon isolation
The body is removed and now the battery packs can be disconnected. Every pack has two wires attached which connect all 4 packs in series.in total there are 100 cells (3,7V) which results in a voltage of 375V. .
DC voltage of battery packs
After the wires and the fiber cables where removed I lifted the packs with a forklift. the motor is mounted on to the original Lotus (Toyota) gearbox. The motor is on the right side under the black round cover.
Battery packs removed
To replace te bad isolation the body shell and two battery packs need to be removed from the car.
Body shell removal
Recently the car wouldn’t start charging and Error Code 5 started showing up. It started intermittently and could be solved by unplugging and plugging the charge cable. Last week it wouldn’t charge at all. The cause of the problem is known, a kind of Pertinax (phenol formaldehyde) is used as isolator between the rotor and the flywheel, when Pertinax ages or gets damaged it gets hygroscopic. To replace te bad isolation the body shell and two battery packs need to be removed from the car.
AC-Propulsion offers a LOM (Lithium Optical Monitor) diagnostic interface. This interface enables you to diagnose one or more LOM modules. I used this interface, which I borrowed, when I replaced a bad cell from the battery pack (see my other post).
Original AC-Propulsion LOM interface
The original interface is based on a CP2102 USB to serial chip, one Single Bilateral Analog Switch and a few transistors and resistors. The blue and black plastic connectors are from Industrial Fiber Optics (IF-E96E and IF-D91). I draw the schematic based on the original Interface and replaced the SMD components with normal sized components. I couldn’t find the DIL version of the SMD bidirectional binary switch (SN74LVC1G66DBVR) so I used the 4066 a Quad Bilateral Analog Switch. To prevent problems with the CP2102 chip I ordered a standard Micro USB to UART TTL Module 6Pin Serial Converter.
LOM interface v1.0
I wanted the Yakazi X1DT0027 CHL-02 ChaDeMo charge inlet but a stagering 650,- USD was a bit to much. I don’t know if I can get the thing running, so I tried to find a cheaper source. I got a charge inlet from a totalled Mitsubishi Outlander PHEV for only 250 Euro.
Mitsubishi Outlander PHEV inlet
The high voltage wires used in the Mitsubishi Quick charge inlet are relatively thin. This is because the charge current of the PHEV is limited to 50A. But for my project it is just fine. If I get the ChaDeMO interface working I can always upgrade the wires to support the max current of 125A.
I was able to find 8 out of the 11 converted Lotus Elise.