EP-1000

DC Motor Controller


We're here to help.

TECHNICAL SUPPORT PAGE

For additional help and support, please call 508-923-9503 during normal business hours (USA-EST) or email us at support@EPC-Corporation.com

References / Manuals



EPC Controller Manual - Installation and operating instructions for all EPC controllers 

EPC Technical Reference Manual - Processor upgrade and service parts list for controllers

 

Battery Charger Manual - Installation and model identifications


12 Volt Battery Chart - Lists state-of-charge voltages for 12-volt lead-acid automotive/marine batteries.  Multiply the voltage by the number of batteries in your pack to obtain the full pack and discharged pack voltages.  We recommend not cycling lead-acid batteries below 50% charge for longest life.


Lithium Battery Reference Chart - Lists most major Lithium Battery chemistries and properties.  This is a general reference; Exact parameters will vary from manufacturer to manufacturer.


Wire/Cable Size AMP Chart - Complete list of the current capacity for all wire sizes.  For wiring with 80C all the way up to 200C-rated insulation.


 

Basic Q & A



Q:  What are the recommended voltage limits for the EP-1000?

A:  Recommended pack voltage for all EPC controllers is 24 to 340 volts.  The absolute maximum values are not listed in the owners manual, however most of our controllers will continue to run all the way down to 11 volts.  All controllers are factory-tested at 400 volts before shipping.
 
 
QHow long is the standard warranty on the EP-1000 controller?

A:   One Year.  Extended warranties are also available.


Q:  Will racing/competition void the warranty on the EP-1000 controller?

A:   No.  If you push the controller beyond its limits, the desaturation detection will automatically power down the controller to prevent damage.   If your controller fails because the desaturation detection did not kick in fast enough, then the controller will be repaired or replaced under warranty. 
 
 
QIs the EP-1000 programmable?

A:  No.  The EP-1000 is factory-programmed and the software cannot be re-configured by the end user.


Q:  Will opening the controller's case void the warranty?

A:   No, as long as you don't touch anything.  The processor is user-replaceable, so we have to allow for the case to be opened.  You can also send in your controller for free software upgrades if you don't want to open your controller (shipping fees apply).
 
 
Q: How hot is too hot?
 
A: If you find that your controller's heatsink regularly exceeds 140 degrees (F) then we recommend adding cooling fans to help dissipate heat.  Or you can just buy a larger controller.  Either way is fine with us.


QAre there provisions in the EP-1000 for cooling fans or liquid cooling?

A:  As shipped, the EP-1000 does not have provisions for liquid cooling.  The EP-1000's heatsink has provisions for two standard 4-inch cooling fans, which can be added if needed.  A special liquid-cooled version of the EP-1000 is also available.


QWhat is the life expectancy of the electrolytic capacitors inside the EP-1000?

A:  If your EP-1000 is equipped with
electrolytic capacitors, you should expect them to last about 10 to 15 years, depend on how much ripple is in your system.


Q
My EP-1000 is equipped with all film capacitors.  Will they last forever?

A:  Pretty much.  But only your great, great, grandchildren will know for sure.


Advanced Q & A



QIs the EP-1000 built on an open source platform? 

A:  No.  However the controller uses a standard Atmel processor (see Technical Reference Manual) which is user-replaceable.  Please note that any internal modifications to the controller -- including the installation of non-factory software -- will void the warranty.
 
 
QCan the EP-1000 drive low inductance motors?

A:  Yes, down to about 10 uH.  Below that, the controller may shut itself down to protect the IGBT modules.  The EP-2000 can drive motors as low as 6 uH.  We also have a special, high frequency (20 kHz) version of the EP-1000 which can go slightly lower.  This version comes with special motor cables designed to run at that frequency.
 
 
QThe software currently installed in my EP-1000 is not ideal for with my application.  Can I have this changed?

A:   We do have some flexibility with the software.  If you need custom software for a specific application, please contact us.  We may be able to adjust the software for your specific application. 

Processor Replacement Instructions

The firmware (which is the software program that runs the controller) is permanently installed in the controller's main processor chip.  To change or update the firmware, the processor must be replaced. 

The EP-1000 and most other EPC controllers are currently running firmware version
1.03a

Controllers that are running previous firmware versions DO NOT need to be upgraded.  NO software bugs have been detected in previous firmware versions, and newer versions DO NOT offer any additional safety features.  The only firmware changes made since the original version involve adjustments to the "soft start" and throttle response algorithms.  These adjustments soften the torque during acceleration to give the impression of driving a gasoline-powered car.

If you would like to upgrade your firmware, you can return your controller to EPC for a free software upgrade (shipping charges apply).  You can also request a free upgraded processor by providing the serial number of your controller.  Processor replacement instructions are provided in the EPC Technical Reference Manual, and are also shown below. 

   
STEP 1:  Locate Main Processor

NOTE:  Although advanced users may be able to access and replace the processor without removing the EMI shield/plate as shown below, we DO NOT recommend this practice.  Accessing the processor without removing the EMI plate is very difficult, and can result in processor or controller damage if not done properly.  This type of damage is NOT covered under the factory warranty.
STEP 2Remove the EMI shield lock nuts

Remove the THREE hex nuts that lock the EMI shield in place.  Please note that the plate is attached by machine screws, and it will NOT move when the nuts have been removed.
STEP 3:  Remove EMI Shield Screws

Remove the THREE external plate screws that are highlighted in photo #3.  Use caution NOT TO REMOVE ANY SCREWS THAT ARE NOT HIGHLIGHTED.  After the screws are removed, carefully remove the EMI plate.
STEP 4:  Replace Processor

Carefully remove the processor (using an approved IC removal tool) and replace with new processor.  Use caution not to bend the pins of the replacement processor during installation.

As with any computer processor, please be sure that the dot (or notch) faces the same direction when you re-install the processor.  The processor WILL fit into the socket backwards, which may damage the processor and/or circuit board.

Replace EMI plate using the original screws, spacers, and nuts.


This page is regularly updated with new information as it becomes available.  For additional support, please contact:

 

EPC Corporation

 

Phone:   508-923-9503       

 

Email:    tech@EPC-Corporation.com

 

 

Shipping address for upgrades/returns:


EPC Corporation
25 Wareham Street - Unit 2-11 
Middleboro, MA  02346
USA