EPC Technical Reference Manual

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EPCDC Motor Speed Control

TECHNICAL

REFERENCE MANUAL


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This manual covers the following EPC controllers:

EP-2000

EP-1000

EP-Junior

NEV Controller


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INTRODUCTION

The EP-Series of motor controllers are suitable for most industrial, automotive, andmarine applications. They are designed to drive most brushed DC motors, includingseries-wound, separately excited, and permanent magnet motors. Separately Excitedmotors may require additional hardware, based on the application.

All EP-Series controllers come configured to run off any DC power source, and can alsobe run from single-phase and three-phase AC power sources with our optional ACModule.

All EPC controllers are designed to operate in harsh industrial environments. Installationis residential environments will require that the high voltage terminals of the unit to be

shielded with a UL-Listed terminal protector or cover.

All EPCProducts are

Manufactured in theUnited States of America


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FEATURES

True plug-and-play design... simply connect and go!

Half the cost of a conventional industrial/automotive controller

Soft-start technology allows for smoother acceleration

100% Waterproof and wet-location compliant

No programming required

Fanless, air-cooled design allows for a very small footprint

Full optical isolation between high voltage and 12-volt systems

Efficient heatsink and IGBT modules eliminate the need for liquid cooling

Wide input voltage range: 72 to 240 volts

Non-metallic enclosure increases safety and prevents corrosion

All stainless steel / brass hardware included

Energy-saving design operates at over 97% efficiency

Brake pedal input for additional safety in the event of throttle bind / failure

Built-in contactor delay allows you to turn on the contactors and controller at thesame time, without the possibility of damaging components

All EPC controllers will automatically detect your motor type, battery pack voltage, andpotentiometer range. Programming is not necessary, except in rare cases where theequipment is being operated outside its normal range. In those cases, the processor will

have to be replaced as outlined in the next few sections.

All EPC controllers use a standard 6-pin wiring harness. This makes it easy to swap orupgrade the controller, without the need to re-wire the controller.


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INSTALLATION INSTRUCTIONS

A typical installation is shown below. If using an AC power source, a DC convertermodule must be placed where the battery is located.

Controller can be installed in any orientation. A fan may be placed at or near theheatsink for additional cooling, in situations where the controller is operating at maximumor near maximum capacity most of the time.


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SPECIAL NOTICE

Always verify that NO HIGH VOLTAGE POTENTIAL is present on the 12 voltbattery/power supply terminals. This can be dangerous to anyone servicing or using the

equipment.

Testing for this condition can be done as follows:

Connect a high voltage meter between each 12 volt battery terminal (or power supply)and each high voltage battery terminal. The meter should read close to zero volts in allcases.

For automotive applications, also check the voltage potential between the chassis/frameof the vehicle and each high voltage battery terminal. The meter should read close tozero volts in all cases.

If there is a high voltage leak anywhere in the system, it must be repaired immediately.All EPC controllers are fully isolated, and cannot leak voltage into the 12-volt system.


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LOW POWER TERMINAL CONNECTION

All low power connections are pre-wired into a 6-pin wiring harness (see Figure 1) foreasy installation. All EPC controllers use the same harness connector, and areinterchangeable.

Pin #1 (WhiteWire)

Connect to the NEGATIVE(-) of your 12 VOLT power supply or battery.

Pin #2 (RedWire)

Connect to the POSITIVE(+) of your 12 VOLT power source. This terminal is used to turn your controller

ON. For electric vehicles, this is typically connected to the ignition switch.

Pin #3 (BlueWire)

Brake Pedal Switch. Accepts +12V DC input to let the controller know that the brake pedal is depressed.This instructs the processor to go down to 0% throttle, regardless of the position of the potentiometer. Ifyour motor is set to run continuously at idle, activating this wire will shut it down until the brake pedal isreleased. Although this connection is optional, we strongly recommend using it for automotive (EV andhybrid) applications.

Pin #4, 5, 6 (Green, Brown, and YellowWires)

Connect to your 3-wire potentiometer. Most standard 0-5k though 0-100k potentiometers can be used.

M = Male PinsF = Female Pins

Figure 1: Controller End Wiring Harness


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POTENTIOMETER CONNECTION

The EP-1000 will auto-detect any standard a 3-wire potentiometer. Any value from 0-5kto 0-100k can be used. Reverse potentiometers (5-0k or 10-0k, for example) may also beused, but wires number 6 and 4 must be reversed. Most two-wire potentiometers (such

as the Curtis PB-5 or PB-6) can also be used if you connect a wire from the third(unconnected) terminal of the potentiometer to the third terminal on the EP-1000s throttleinput (pin #6). To do this, you must first open the potentiometers enclosure to gainaccess to the terminals and solder a wire to the unused potentiometer terminal.

All EPC brand potentiometers are 3-wire, and come with a 6-pin EPC harness pre-installed. Due to their accuracy and high quality construction, we strongly recommendusing only EPC potentiometer units with this controller. Low quality potentiometers canresult in poor motor speed control, uneven throttle response, and often have a very shortlifespan.

Although an improperly connected potentiometer will not damage the controller itself, itcould cause the controller to apply full power to the motor. This condition will cause themotor to operate at an unsafe speed, which could damage or even destroy the motor.Care should be taken not to power up the controller until proper installation of thepotentiometer is verified. A diagnostic device (such as a duty cycle meter) can be used toshow power output before connecting your motor. In some cases, a dummy load (such

as a heater or light bulb) can beused in place of the motor, as longas the device is rated for the linevoltage that you are using.

Please call technical support at508-923-9503 if you have difficultywith your potentiometerconnections.


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INTERNAL HARNESS CONNECTION

NOTE: Wiring harness colors may change inside of the controller, however the pin orderis always the same. Replacement wiring harnesses assemblies are available directlyfrom EPC.


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MAIN SYSTEM BOARD

Figure 5 Main system board. Minor components removed for clarity.

Please note that the IGBT Driver Modulesare NOT replaceable. Because of thesophisticated hardware/software protection built into these modules, module failure isvirtually impossible. In the unlikely event of a driver module failure, the module(s) mustbe professionally replaced. EPC does NOT recommend replacing these modules in theevent of a failure. In such a case, the entire motherboard assembly should be replaced.The motherboard is available as a complete replacement assembly from EPCCorporation.

The NEV Controller, EP-Junior, and most EP-1000 controllers only contain ONE drivermodule. The EP-2000, and special versions of the EP-1000 (such as the high frequencyversion) use TWO driver modules.


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PROCESSOR REPLACEMENT

Under normal circumstances, the main processor should never have to be replacedunless a software update is required. The processor is pre-programmed from the factory,and designed to outlast the equipment it operates. Processor replacement is onlyrequired if:

Processor Stops Functioning

Internal Programming is Corrupt

Equipment Requires a Software Update

The processor is installed in a 28-pin socket (8-pin for the NEV controller), and is easilyremovable. When replacing the processor, BE SURE to install it with the notch (or dot)facing the same direction. These indicators are visible in the pictures below.

AT-MEGA328 (most common) AT-Tiny85 Processor,Processor, Found in most EPjr Found in NEV Controllersand EP-1000 Controllers

Software updates are available from EPC Corporation, if needed. More information onsoftware updates is available online at www.EP-1000.com


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INTERNAL COMPONENT IDENTIFICATION

EP-Junior

Figure 6 EP-Junior Controller

Internal components of the EPjr are visible in this photograph. EMI shields, cables, and

minor components have been removed for clarity. Please note that the controller aboveis a training model for service technicians; Actual production components and locationsmay vary slightly. Please use the part numbers on the next two pages when servicing.


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INTERNAL COMPONENT IDENTIFICATION

(CONTINUED)

Internal components for the EPjr are shown in Figure 6of the previous page. Other thanthe main processor, the internal components of these controllers are NOT user-

serviceable. The following part numbers are provided for authorized service techniciansonly.

The replaceable system processor is located on the Main System Board (electronicsboard). When replacing the processor, use caution not to damage the surroundingelectronic components.

REPLACEMENT PART NUMBERS

EP-Junior (Prior to 2011)

OEM PART # Description for Replacement (including limits)

PowerEx CM600HA-24A IGBT Module 1200V / 600APowerEx RM300HA-24S Freewheel Diode Module - 300V / 300AEPCOS B43991-A4208-Q1 Electrolytic Capacitor 2000uf / 400 to 450VTPC FSG86-9302 Film Capacitor 100 to 200uf / 600 to 1200VAerovox RBPS Snubber Capacitor - 2.0 to 3.0uf / 800 to 1200VEPC EPJR-MB Processor and Control Board for IGBT

TDK PH-FF Power Supply +20VEPC EPJR-H2 Wiring Harness (includes bulkhead)

EP-Junior (2011 - 2014)

OEM PART # Description for Replacement (including limits)

PowerEx CM600E3U-NFH IGBT Module 600V / 600AEPCOS B43991-A4208-Q1 Electrolytic Capacitor 2000uf / 400 to 450VTPC FSG86-9302 Film Capacitor 100 to 200uf / 600 to 1200V

Aerovox RBPS Snubber Capacitor - 2.0 to 3.0uf / 800 to 1200VEPC EPJR-MB Processor and Control Board for IGBTPowerEx VLA502-02 IGBT Gate Driver (mounted on EPJR-MB)EPC EPJR-H2 Wiring Harness (includes bulkhead)


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REPLACEMENT PART NUMBERS

EP-1000 (Prior to 2010)

MANUFACTURER PART # QTY DESCRIPTION

PowerEx CM600HA-24A 2 IGBT ModulePowerEx RM400HA-24S 1 Freewheel Diode ModuleEPCOS B43991-A4208-Q1 2 Electrolytic CapacitorTPC FSG86-9302 2 Film CapacitorAerovox RBPS 3 Snubber CapacitorTDK PH-FF 1 Power SupplyEPC EP1-MB 1 Processor and Control BoardEPC EPJR-H2 1 Wiring Harness (includes

bulkhead and connector)

EP-1000 (2010 - 2014)

MANUFACTURER PART # QTY DESCRIPTION

PowerEx CM600E3U-NFH 2 IGBT ModuleEPCOS B43991-A4208-Q1 2 Electrolytic CapacitorTPC FSG86-9302 2 Film CapacitorAerovox RBPS 4 Snubber CapacitorEPC EP1-MB 1 Processor and Control BoardPowerEx VLA502-02 2 IGBT Gate Driver (on EP1-MB)EPC EPJR-H2 1 Wiring Harness (includes

bulkhead and connector)


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CONTROLLER PROTECTION

FUSE PROTECTION

Please note that a standard AC fuse should NOT be used in a DC circuit. The fuse mustbe SPECIFICALLY labeled for DC applications. For most larger motor applications, a600A fuse will be sufficient. Application-specific fuses can be ordered directly from EPC.

Also note that standard 125-volt and 240-volt DC circuit breakers (such as the AirPaxJLM-1-1RLS5-30140-200) will NOT function correctly because of the high voltage presentwhen the motors windings are discharged during normal operation. If using a circuitbreaker, it must have a DC break rating higher than 600 volts.

NO YES NO

CONTACTORS

A pair of contactors, or some other type of high-speed mechanical disconnect should beinstalled near the power supply. This not only allows for easy servicing, but can protectthe motor and controller in the event of a short or system failure. Contactors areREQUIRED for all electric vehicles running DC motors.

Pictured is a Curtis SW-200 Contractor. Contactors shouldhave a continuous rating of at least 200 amps, with a surgecapacity of about 1000 for this controller. Magnetic

blowouts are required.


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WET LOCATIONS

Although all EPC controllers are water resistant, care should be taken during installationto protect any exposed high voltage terminals. The standard NEMA enclosure used forall EPC controllers protects the internal components, and is completely sealed from the

environment.

EP-1000 / EP-2000

The EP-1000 may be briefly submersed whilerunning.

All external connections should be protectedfrom the environment by installing optional

protection boots, as shown here. Theseboots are available from directly from EPCand most other industrial componentsuppliers.

EP-Junior / NEV Controller

The EP-Junior and NeighborhoodElectric Vehicle controllers come withpre-installed motor and battery cablesfor easy installation. The cables areinstalled using water-tight connections,as shown to the right.

This allows the controller to operatewhile submersed, without the possibilityof voltage leaking into the water.


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HEATSINK DATA

(EP-1000)

Material: Extruded AluminumWidth: 10.000"Length: 12.000Fin Height: 1.000"Base: .300"C/W/3": approximately 0.90Weight per Inch: 0.48 lbs


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ENCLOSURE DATA

CONTROLLER NEV EP-Junior EP-100


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EPC Technical Reference Manual

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