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WarP-Drive |
NetGain Controls, Inc. has released its long-awaited high voltage, high-Amp controller! |
User Manual pre 28-Jan-10
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User Manual
28-Jan-10
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Installation
Diagram - Minimal
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Installation
Diagram - Redundant Contactor
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Installation
Diagram - Redundant Contactor and Dual Main
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With over a half-megawatt of power output capability and its professional quality, this silent powerhouse is the new controller of choice! Designed with ruggedness in mind, and ease of use, it is the perfect controller for hobbyists and OEMs alike. The WarP-Drive has the quality you would expect from a NetGain product, at a price you can afford.
The base unit comes programmed for 1000A continuous rated output at 160V, and is user-upgradeable to 1200 and 1400 amps and 260 and 360 volts. The WarP-Drive comes from the factory with CANbus connectivity, which gives it endless capabilities to operate in conjunction with already-in-development third-party hardware solutions. Additional information on features is provided in the sections below.
Shipping on all WarP-Drive controllers is $30 within the US.
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160V |
260V |
360V |
1000A
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| 1200A |
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| 1400A |
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| Additional 100 Input Volts (Field Upgrade) |
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| Additional 200 Output Amps (Field Upgrade) |
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Variable Current Input/Output
A single WarP-Drive unit can be configured to output up to 1400 amps. The base unit starts out at 1000 amps with 200 amp upgrades available until 1400 amps.
The input and output current can be set to whatever limits you want using the NetGain Controls Interface Module. This feature can be used to protect your batteries, while providing you with the most power output possible. |
Variable DC Voltage Input/Output
The unit can be initially purchased with 160, 260, or 360V nominal limits. Customers can purchase upgrades at any time that allow the end-user to perform the upgrade. This versatility allows customers to start with a feature-packed controller, and scale to higher pack voltages as budget allows.
The output voltage (motor voltage) can be configured using the NetGain Controls Interface Module to limit the voltage that the motor sees. This is especially useful for higher pack voltages used with motors that are limited (such as the NetGain WarP, ImPulse, and TransWarP, which have a limit of 160-170V). |
OEM Quality
When you show off your new electric vehicle, you don't want the on-lookers thinking they are at a middle-school science fair! The WarP-Drive takes several steps to provide factory quality, with a "show-off" flair! Waterproof automotive connectors and its water-resistant case make it suitable for installation under the hood. The flame-proof polycarbonate cover reveals the internals, displaying what it takes to dish out all that power. Use of the industry-standard communications protocol "CANbus" make it compatible with hardware of the future that hasn't even been developed yet. |
Liquid Cooling
The best controllers on the market use liquid cooling to wick away the heat produced. The WarP-Drive uses precision machined liquid chill plates. Connecting to the chill plate is extremely easy! No fiddling with hose clamps - simply "plug" a 3/8" OD vinyl hose into the quick connections and you're done! We also carry a custom cooling kit for the WarP-Drive. This kit can be installed in under an hour. |
Economical
For a price of $1950, a base controller (160V, 1000A) can be purchased today. A few thousand miles later, when you're ready and can afford more power, firmware upgrades can be purchased to allow more power or a larger battery pack. |
Hall Effect Pedal Input
The WarP-Drive exclusively uses a Hall-effect throttle input (no 0-5kohm "potboxes"!). NetGain Controls provides two types of throttle assemblies. One is a complete pedal unit. And for those who have used a pot-box in the past or those simply not wanting to change out the original accelerator pedal, a unit is available that can connect to the existing throttle cable.
The WarP-Drive can also be programmed to accept a Hall-Effect Pedal used with the Zilla controler. |
Safe, Durable Connections
Consumer safety was of utmost priority when designing the WarP-Drive. As such, the high voltage terminals on the controller were placed on top, with generous distances separating them. When connecting terminals are outfitted with protective boots, this setup decreases the chance of a dropped tool arcing across terminals. Connecting and disconnecting the main power cables is much safer, as a single hand can be used.
Throttle, precharging, and data output terminals on the controller's front are automotive quality, waterproof connectors. Although the controller should be located away from frequent direct exposure to liquids, it can take splashings without any problems. |
External Construction Optimized for Size, Weight, Function, and Durability
The WarP-Drive weighs in at just under 16.5lbs (7.5kg)! It is approximately 6 " high (to top of capscrews), 9" wide, and 10.75" long. All core functionality is built into the single unit, eliminating the need to mount multiple enclosures.
The WarP-Drive's base plate and side plates are made of anodized aluminum. These plates are not only visually appealing, they also act as an extra heat sink to wick away heat.
The clear plastic cover is made of the highest flammability rated polycarbonate (UL94V-0). Besides resisting burning, the cover also resists warping due to sun exposure. At about 1/8" thick, the cover is almost impervious to shattering or denting.
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Temperature Safety
Designed for any temperature situation, the WarP-Drive internally protects itself from overheating. When using the available cooling kits, temperatures can usually be limited to below 55C. However, some situations can arise causing the temperatures to rise above this (e.g. a pump failure). At 55C, maximum power output capability is decreased. At 80 Celsius, the controller begins to more aggressively reduce power output. At 100C, the amp-output capability hits zero. |
The Quality You'd Expect From NetGain
The WarP-Drive controller by NetGain Controls, Inc., has the quality you would expect from the NetGain name. The unit is built with the highest quality components, and assembled in a professional electronics assembly facility. |
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