Motor Controller Help needed

[usabug]

Hi everyone. I am in the process of building an electric go Kart. I am in need of help with the motor controller. I reached out to Curtis regarding help with a motor controller and they referred me to a guy that has been difficult to get ahold of and work with. If anyone has some advice or can offer help I would appreciate it. I will compensate for time.

Here are the motor specs:

D&D Motor Sport Motor:
24VDC, 2600RPM
95 AMP/armature
8.0 AMP/Field
2.3 HP
S2-60min
EE
Clas H -180 C

Motor Field Weakening Limitations map attached.

The motor controller that Curtis recommended was the 1243. If anyone has a different controller that would work I would welcome their opinions.

Thanks in advance.
Dean

 

[Functional Artist]

Howdy & welcome

It looks like you have a sep-ex (separately excited) type motor
...so, you don't have many (low cost) options available

Also, running a kart @ 24V doesn't usually make a very fast or fun kart

So, IMO your gonna want @ 48V or maybe even 60V set up

For more info, check out my Excalibur kart

2020 - Excalibur Electric Racing kart

I watched a movie the other day with the family, called "Go Kart's" :thumbsup: ...it was about go kart racing :auto: I must have told my wife (10) times "I could do that" :wai: ...not really racing (well maybe, who's gonna test 'er) ...but, to build a racing (style) kart...

www.diygokarts.com

 

[usabug]

Thanks. This is not going to be a fast Go Kart. This is for parade shows/ car shows.

Dean

 

[itsid]

Not entirely sure if your motor is capable of a series configuration..
if it is, you can pick a KD -series Kellycontroller
(like the KDS24200E [200A peak, 120A continuous]) for 120 bucks
it's only 30 bucks more than the 100A peak version and provides quite a bit of added reliability especially for non permanent magnet motors.
(programmable for current limiting and ramping speeds if needed)
maybe check the manual first:

https://kellycontroller.com/wp-content/uploads/kds/KellyKDSUserManual.pdf

there's also a higher valued KDZ Controller (160 dollar w/o and 180 with Regen function)
KDZ24200 or KDZ24201 with regen

again take a look at the manual first

https://kellycontroller.com/wp-content/uploads/kdz/KellyKDZUserManual.pdf

I'm fairly confident that you can wire your SepEx Motor to those controllers,
but it's a series configuration really.. so all coils (rotor[amature] and stator) are toggled at the exact same time
Sep Ex allows for individual and seperate exitation (hence the name)
So you might gain a bit of torque if the stator is actually powered at all times (acting more like a permanent magnet)
and maybe even a hair extra if you can switch it of when the rotor is inbetween two states (reducing the internal drag)

Since Curtis Controllers are usually on the expensive side of the chart, you might want to make use
of their benefit (not reading the manual for the 1243 to see if there are any)
or you might want to just give the kellies a go and see if it's sufficient for your needs.

'sid

PS Kevin, you have a KDS, right? Any insights you might want to share about it or it's capabilities in terms of programming and such?

 

[Functional Artist]

Not entirely sure if your motor is capable of a series configuration..
if it is, you can pick a KD -series Kellycontroller
(like the KDS24200E [200A peak, 120A continuous]) for 120 bucks
it's only 30 bucks more than the 100A peak version and provides quite a bit of added reliability especially for non permanent magnet motors.
(programmable for current limiting and ramping speeds if needed)
maybe check the manual first:

https://kellycontroller.com/wp-content/uploads/kds/KellyKDSUserManual.pdf

there's also a higher valued KDZ Controller (160 dollar w/o and 180 with Regen function)
KDZ24200 or KDZ24201 with regen

again take a look at the manual first

https://kellycontroller.com/wp-content/uploads/kdz/KellyKDZUserManual.pdf

I'm fairly confident that you can wire your SepEx Motor to those controllers,
but it's a series configuration really.. so all coils (rotor[amature] and stator) are toggled at the exact same time
Sep Ex allows for individual and seperate exitation (hence the name)
So you might gain a bit of torque if the stator is actually powered at all times (acting more like a permanent magnet)
and maybe even a hair extra if you can switch it of when the rotor is inbetween two states (reducing the internal drag)

Since Curtis Controllers are usually on the expensive side of the chart, you might want to make use
of their benefit (not reading the manual for the 1243 to see if there are any)
or you might want to just give the kellies a go and see if it's sufficient for your needs.

'sid

PS Kevin, you have a KDS, right? Any insights you might want to share about it or it's capabilities in terms of programming and such?

Hey Sid
I have a Kelly Controls KDZ72550 controller on my El Moto

Their pretty simple to install, works great & I've never had any problems
(put almost 700 miles on 'er since converting to electric)

* Actually I've never done any programming
...I just hooked 'er up & went
(maybe I should look into that)

 

[itsid]

Ah.. my mistake.. KDZ noct KDS..
At least it's still the KD<something> that's also capable of powering series wound motors
or SepEx motors (with the drawback of not being able to actually seperately exite the stator from the armature coils)

* Actually I've never done any programming
...I just hooked 'er up & went
(maybe I should look into that)

Do you have the software on your computer?
If so maybe you can take a peek around the settings
or even take a few screenshots
that might give us a good enough clue what's actually doable for usabug *shrugs*

'sid

 

[usabug]

Thanks guys. I will check out Kelly controllers. Much appreciated.

Dean