Pioneer Conversions

1
Pioneer Conversions

• Presents
• EV Controller
• Comparison

2
What is the Controller?

• EV Controlers send full pack voltage to the
  electric traction motor.
• EV Controllers create microsecond long pulses of
  electricity, longer when the accelerator pedal is
  fully pressed, shorter when the accelerator pedal
  is lightly pressed.

3
Let's define some terms

• Pot box Potentiometer, or variable resistor.
• Hall Effect the production of a voltage
  difference in a conductor, caused by the movement
  of a magnet. Usually much less prone to failure
  over years of use

4
Signaling the Controller

• Can be done with Pot Box(usually 0-5K)
  (occasionally 5-0K)
• Can be done with variable voltage (usually 0-5V)
• Can be done with Hall Effect Sensors
• Control device may incorporate microswitch

5
Controller Amperages

• Most are rated at continuous amperages
• Continuous amperages may be a 10 or 15 or 30
  second rating
• Rating time might not be important
• Most, but not all are determined by hardware used
  during construction
• At least one is rated for several amperages on
  same hardware, with higher amperages needing a
  software unlock.

6
Controller Voltages

• Rated for nominal pack voltage
• Should check with manufacturer if your charged
  pack voltage is considerably different than
  nominal.
• Example 45 LiFePO4 cells have a nominal voltage
  of 3.2V per cell or 144V nominal for the pack.
  Fully charged, the float voltage of the same pack
  would be 3.9V per cell or 175.5V nominal.

7
Controller Cooling

• Highest amperage units require liquid cooling
• Cooling will mean pump, resevoir, plumbing, may
  mean small 120mm radiator
• Middle amperage units may use fans, heatsinks or
  combination
• Lower amperage units may not need fans

8
Other Controller Inputs

• Some take tachometer input to prevent overspeed
• Some can run the motor at low RPM as idle
  function for automatic transmission when
  transmission is in Drive
• Some have possible cutback on brake input
• Some have inputs from reverse or valet key

9
Controller Low Amp Outputs

• Trigger main contactor delay for precharge
  resistor
• Warning light power on
• Warning light full throttle
• Warning light controller cutback

• Feed for tachometer
• Data displays for amps, volts, temp
• Triggers for cooling
• Triggers for set data limits
• Data acquisition
• CAN bus

10
Look at what is on the market

• Curtis
• Raptor
• Logisystems (and the WarP-Core)
• All names here are registered trademarks of their
  respective owners.

• Solitron 1
• Zilla
• WarP-Drive

11
Controller - Curtis

• Up to 550A 120V
• Up to 500A 144V
• Air cooled
• 0-5K Pot box
• KSI needs pack voltage
• Needs precharge resistor

12
Controller - Raptor

• 156V
• 1200 Amps
• Air cooled
• 0-5K Pot box
• Optional 3 LED display, power, full
  throttle, in thermal cutback

13
Controller - LogiSystems

• 72-120V or 120-144V or 144-156V
• 550 or 750 or 1000 Amps
• Air cooled, comes with heatsink and fans
• 0-5K Pot box, special Pot available

14
Controller - LogiSystems

• Benefits from precharge resistor
• Amperage and voltage specified on order
• ¼ inch spade terminals for low amp.
• KSI needs pack voltage

15
Logisystems ? WarP-Core

• Red Anodized finish
• Special Pot Box included
• Distributed by NetGain Controls
• Not just a pig with red lipstick

16
Controller Solitron 1

• 300V
• 1000 Amps
• Liquid cooled
• Input Pot box 0-5K, 0-5V, or Hall Effect
• KSI - 12V

17
Controller Solitron 1

• Tach input, can protect from overspeed, or can
  idle motor for Auto. Trans.
• Brake input
• Reverse Input

18
Controller Solitron 1

• Three programmable outputs for driving meters,
  contactors, relays, buzzers, whatever, as long
  the device runs on 12V nominal and uses less than
  1A

19
Controller Solitron 1

• Liquid cooling not mandatory, but controller
  cutsback on high temps.
• 1400 amps may be unlocked with special racing
  agreement and waiver

20
Controller - Zilla

• LV up to 156V
• HV up to 300V
• EHV up to 360V
• 1000 or 2000 Amps
• Liquid cooled
• Uses Hairball for low amp. connections

21
Controller - Zilla

• Can order Hairball for pot box OR Hall Effect
• Tach input
• Tach output
• Many output possibilities
• Z2K-EHV is 5,075

22
Controller - Zilla

• Hairball offloads low amp connections with
  screw connections

23
Controller - WarP-Drive

• 160V or 260V or 360V
• 1000 Amps or 1200 Amps or 1400 Amps
• Liquid cooled
• Hall Effect only
• High amperage contacts on top

24
Controller - WarP-Drive

• Controller is software upgradable to higher
  amperage or voltage
• Components are very high quality, even in base
  unit
• Dealer upgradable any time after purchase

25
Controller - WarP-Drive

• Water resistant auto-motive type connections
• Two CANbus water resistant ports for
  communication
• Push connections for liquid cooling connections

26
Controller - WarP-Drive

• CANbus supports motor amps, controller amps,
  batt. Voltage, controller temp. full data
  acquisition, other displays
• Will be able to accept alternative input on
  CANbus

27
Controllers What's Important

• Get recommendations from several sources
• Consider what the total costs are (include
  cooling, input devices
• Minor consideration for connections
• Major consideration for quality

• You get to choose
• Discuss with people who have already driven one
• Drive a similar one yourself
• Read EVAlbum

28
Controllers Where to get info

• Curtis http//curtisinst.com/
• Raptor http//pioneerconversions.com/catalog/pr
  oduct_info.php?products_id29osCsida8fcc54797d77
  479881eda959344946f
• Logisystems (and the WarP-Core)
  http//evie-systems.com/index.php?main_pageindex
  cPath52_53
• Solitron 1 http//www.evnetics.com/soliton1speci
  fications.html
• Zilla http//www.evcomponents.com/SearchResults.a
  sp?Cat52
• WarP-Drive http//www.ngcontrols.com/WarP-Drive.
  html