My EV Conversion Journey and the Greenwheel Challenge

[Betoarmenia]

Hello everyone,


I’m working on converting my 2008 Chery QQ to an electric vehicle and could really use some advice from this amazing community. I purchased the system second-hand, which includes a 72V setup with an asynchronous AC motor (with an HEDS-5645 encoder) and a battery pack (likely lead-acid, though I’m still confirming capacity). The exact power rating of the motor is unknown—I initially estimated around 5 kW based on the controller, but I’d love help confirming this. The original controller was a Greenwheel LF-P06-1, but the system never ran in my hands. I discovered that the cables were poorly cut before I acquired it, and there’s no documentation or wiring guide to work with.


I’ve been attempting to reverse-engineer the connections using a multimeter, analyzing the controller’s PCB, and studying photos of the setup (I can share them if needed). The lack of information on the Greenwheel LF-P06-1 is a major hurdle—there’s almost nothing online about its pinouts, specs, or configuration. I’ve managed to map some terminals (B+, B-, U, V, W) and the encoder signals (+5V, GND, A, B), but without a manual, progress has been slow. Given the condition of the system when I got it, I decided to upgrade for reliability.


New Development: Switching to Curtis 1238-6501


I recently purchased a Curtis 1238-6501 (48-80V, 550A) to replace the Greenwheel. It seems like a good match for my 72V system, but I’m now tackling the challenge of adapting it. I’ve started mapping its terminals, but I don’t have a programmer for the Curtis (like the 1313-4331) or access to the VCL software to configure it. I’m unsure about the best settings for my motor and encoder, though the Curtis manual has been somewhat helpful.


What I Need Help With:


1. Greenwheel LF-P06-1 Info: Has anyone worked with this controller? Any pinout diagrams, manuals, or experience to share? I’d love to salvage it as a backup.


2. Motor Power Identification: Can anyone help me identify the exact kW rating of my AC motor? I’d appreciate advice on how to test or estimate it (e.g., based on current draw, RPM, or controller specs).


3. Curtis 1238-6501 Programming Advice: Since I don’t have a programmer, can anyone guide me on how to program this controller for an unknown kW AC motor and HEDS-5645 encoder? What settings should I prioritize (e.g., current limits, speed, encoder feedback)? Also, any tips on where to get a programmer or software access affordably?


4. General Conversion Tips: Any suggestions for integrating this into the Chery QQ, managing heat, or improving efficiency?


I’ve attached some photos of the Greenwheel PCB, motor setup, and Curtis controller for reference. I’m happy to provide more details or test results as I go. This community has been a great resource, so any guidance would be hugely appreciated—I’m determined to get this QQ rolling for the first time under my ownership!


Thanks in advance,
Betoarmenia

 

[amberwolf]

and a battery pack (likely lead-acid, though I’m still confirming capacity).

You'll want to confirm the chemistry, as how you charge it will be based on that, and what charger you will use.

It will also matter for how it is discharged, how much current you can use from it (battery-side current limits in controller), etc. and how much of it's capacity you can actually use. If it's LA you probably wont' get more than half the nameplate Ah, and that is assuming it's actually brand new and has not sat around at less than completely fully charged for any amount of time.

2. Motor Power Identification: Can anyone help me identify the exact kW rating of my AC motor? I’d appreciate advice on how to test or estimate it (e.g., based on current draw, RPM, or controller specs).

What did it come from? Most powered devices and vehicles have a power rating, so you could guesstimate that that is it's definite capability. Most motors can be used for brief periods beyond their nameplate ratings (how brief depends on a lot of things).

3. Curtis 1238-6501 Programming Advice: Since I don’t have a programmer, can anyone guide me on how to program this controller for an unknown kW AC motor and HEDS-5645 encoder? What settings should I prioritize (e.g., current limits, speed, encoder feedback)? Also, any tips on where to get a programmer or software access affordably?

If it requires specific software, you'd have to get that from the controller manufacturer or one of their dealers, or find out what the specific program yours requires is called and see if it has ever been posted anywhere (if it's something you have to purchase from them, they would probably justifiably hunt down such postings and take them down, so probably won't be out there).

If it just uses a serial port to access a terminal page (like the Lebowski DIY controller, etc) or upload a text based settings file, etc., then you just have to have a terminal program on the computer.

What programmer does it require? If it's specific to that controller, and not just a usb-serial or usb-canbus or similar, you'd have to buy one from the controller manufacturer or one of their dealers, or from someone that is selling their used item (assuming they can be resold and are not locked in some way to the person that buys them).

What output does the encoder create? Is the controller you have compatible with that output?

As for settings to "prioritize", you kinda have to set up all the settings in a controller to match your particular setup. Anything you leave at defaults you need to be sure that matches your hardware and usage.

If it doesn't come preprogrammed to work with your specific hardware, including whatever motor settings / properties / etc are required, then it can't be used until you program it to do so. Most "advanced" programmable controllers have to be setup for the things they're going to be used with, and may not have any "usable defaults" that "just work".

4. General Conversion Tips: Any suggestions for integrating this into the Chery QQ, managing heat, or improving efficiency?

What is your specific plan for the conversion, mechanically, electrically, etc?