Controllers

Why do you only use a Sevcon Controller?

Sevcon, also known as Tech / Ops, builds a variety of controllers and electrical components for electric vehicles.    Their products are very efficient and very reliable.

What are the benefits of the Gen 4 controller?

The Gen 4 was the introduces in 2010 and represents the latest in high efficiency, high power controllers.   It features a waterproof snap in plug, is water resistant, and has well laid out terminals for connecting the battery cables and the motor cables.    Propulsion Marine was the first company to use the Gen 4 controller and contributed to the initial programming for the marine applications.    So far there have been zero failures in the field for this tough and reliable PMAC motor controller.

What is unique about the Gen 4 controller software?

The Gen 4 was designed from scratch to run Permanent Magnet motors.   Permanent magnet motor controllers are more difficult to build and characterize than other types of motors.   Characterization is the process that application engineers employ to program the controller to run a specific motor.   The Gen 4 has many different settings to allow the engineers to accurately program the controller so the motor runs efficiently and produces the maximum amount of power.

The Gen 4 senses the temperature of the motor and starts a fan when it reaches a certain programmable temperature.

The Gen 4 senses the temperature of the motor and enters into a thermal cutback if the motor starts overheating.   After it reaches its setpoint, the Gen 4 will cut back 10 % of total system power for every degree above the setpoint.

Why do you include a Clearview Display in each of your Electric Drives?

The Clearview display gives us all the information we require to tune a drive after it is installed.    Electric Drives work best when the AC currents going to the motor are similar to the DC currents coming from the batteries.    If the AC currents are far greater than the DC currents, then the gear ratio needs to be increased so less load is put on the electric motor.   The Clearview display gives motor rpm, torque, and temperature,  controller temperature and battery voltage.     This information keeps you informed on the status of your drive at all times.

The Clearview Display also provides fault management.   It will alert the operator of an over temperature or temperature cutback condition.   Without the Clearview an operator has to interpret a flashing L.E.D. to find out what the fault might be.

The Clearview Display allows for field programming of various functions of the controller by a Propulsion Marine representative.   Inquire for details on this option.

Can the Gen 4 controller be hooked up to the internet?

With the USB to CAN adapter, the Gen 4 can be hooked up to a computer on the internet.    Propulsion Marine can then log into that computer for diagnostics and analysis of your system.    We can upgrade your system to new versions of software if you choose to install a different electric motor in the future.   We can upgrade to new versions of Code for the Clearview display.

Describe how the Gen 4 is wired into the system?

The Gen 4 controller is the central hub of the entire electric propulsion system.    All of the peripherals are connected into the Gen 4.   The Gen 4 is the heart and brains of the electric propulsion system.

How should I mount the Gen 4 to my boat?

The Gen 4 should be mounted to an aluminum plate 1/4 inch thick spaced away from the bulkhead at least an inch, to provide for heat sinking of the controller.    The controller should have a thin film of heat sink paste added between the controller and the aluminum heat sink plate.     This keeps the controller as cool as possible for more efficient operation.    The controller should be mounted away from the immediate vicinity of the motor so the motor and the controller do not share the same heat space.   If this is not possible, it is important that both the controller and the motor have adequate ventilation.