Replacing a Soleq EVcort Motor Controller

By Tim Wong

Technical Information

This section contains schematics and other technical information concerning the parts used in replacing the Soleq EVcort sepex motor controller with a pair of Kelly controllers.

Schematics:

Click here for power schematic pdf file

Click here for control schematic pdf file

Part Information:

Kelly Armature Controller: KDH12801B

Kelly Field Controller: KDH14030 (may be better to get one that enables armature at 2A!)

Accel/Regen Potentiometers: Bourns 6639S-1-502

Field Accel Potentiometer: Single turn 2.5Kohm pot with knurled knob.

12V DC-DC converter to power Kelly controllers: Astec AEE01B18-L (it passed hi pot testing at 1500vdc)

Main contactor latching relay: Potter-Brumfield KUEP-11D15-12

DC-DC converter solid state relay: Crydom D2D12

Controller Configuration:

The Kelly controllers can be configured using a serial port. I wired the serial ports to a remote box to allow for configuration. Here is the setting I found to work well with my system. Each configuration page is a page in the Kelly configuration program.

Armature Controller KDH12801B Configuration:

Page 1 Config. Program:

Model:KDH12801B

Throttle footswitch: Enabled

Throttle sensor type: 0-5V

Throttle low end dead zone: 10%

Throttle high end dead zone: 100%

Max Current: 100%

Page 2 Config. Program:

Controller startup wait time: .7sec

Control mode: Torque

Under voltage: 90V

Over voltage: 125V

Throttle up/down rate: 4 (highest 1, lowest 20)

High pedal disable: Enabled

Page 3 Config. Program:

Top speed: 100%

Page 4 Config. Program:

Regeneration: Enabled

Regeneration brake switch: Enabled

TPS regen switch: Disabled

Regeneration phase current brake switch: 20% (instant regen when brake switch closes)

Max regeneration phase current: 100%

Brake sensor type: 0-5V

Brake low end dead zone: 20%

Brake high end dead zone: 90%

Page 5 Config Program:

Motor temperature sensor: Disable

Field Controller KDH14030 Configuration:

Page 1 Config. Program:

Model:KDH14030

Throttle footswitch: Enabled

Throttle sensor type: 0-5V

Throttle low end dead zone: 40% (this is because the field knob starts at 2.5V)

Throttle high end dead zone: 100%

Max Current: 60% (100% should be 30A. 60% seems to be about 12A)

Page 2 Config. Program:

Controller startup wait time: .5sec (armature controller is .7sec. I wanted field to come on first)

Control mode: Torque

Under voltage: 80V (arm is 90v - that will set pack volt min. I don't want field to Shut off low voltage before arm)

Over voltage: 130V (arm is 125. it will limit pack volt to 125; field will not turn off Before arm)

Throttle up/down rate: 10 (highest 1, lowest 20. too high and regen is choppy)

High pedal disable: Enabled

Page 3 Config. Program:

Top speed: 100%

Page 5 Config Program:

Motor temperature sensor: Disable