[jackbauer]

Ok schematic attached. Not pritty best i can manage for now. The "CON" contacts are a large 50amp contactor controlled but the small relay onboard the sparkfun board. This takes care of switching and precharge in one package. Also in this revision the power is totally off until a charge cycle is engaged.

The 12v psu is a power brick from a scrap portable tv. Also included is an inhibit relay to stop the car from turning on while on charge. The 15mH main inductor is the hf transformer from a scrap 50amp inverter plasma cutter with its primary and secondary in series and in phase. The choke is a laminated unit from the same plasma cutter. Diodes are 150amp fast recovery modules from a scrap inverter welder.

IGBT is a 150amp fuji 2mbi150 module. A miller clamp circuit is used on the driver to improve switching tails. Both diodes and igbt are mounted on a heatsink and fan cooled using parts from the plasma. No noticable heat is generated since igbt drive upgrade. Not on the power section battery output diagram are two mkp caps. one is a 1uf 1000v part the other a 500v 50uf.