Using my new high side DC control board/driver in solar charger

[MPaulHolmes]

I've got like 10 control boards and driver boards for the 1000amp high side controller. One of the advantages of the high side configuration is that you can use it as a buck charger. A different power section is necessary though because of the higher voltage used in charging. Here's a layout. Basically I'm just using one of the 6 isolated supplies from the driver board to turn on/off the single mosfet I'm using. It's so simple when powered from a solar array. Just do 100% duty on the mosfet until the voltage comes up to around 13.8v per battery, then hold the voltage constant until the current falls to "x", then drop the duty down until the voltage per battery is around 13.6 or 13.7. Easy peasy japanesy! With a single diode/mosfet ($20 for diode, $38 for mosfet), you can charge at a rate of around 9 or 10kW. You don't have to have much in the way of input filter capacitor, because it's DC input!

I just ordered the rest of the parts for the charger/inverter. The inverter has has outputs of 110v, 110v & 220v. But what I'll probably do is just use the 220v, fed into a 220v voltage stabilizer, and then plug that into a 4 wire 50amp generator plug.

[thingstodo]

I went through Paul and Sabrinas ev stuff.com - I can't find the 1000A control boards and driver boards.

[MPaulHolmes]

Ya, they're just sitting in my garage. I haven't added them to the store because I haven't gotten around to testing the power section at high amps with my new fancy pants soldering technique for the backs of the mosfets/diodes. I got sidetracked with the whole solar thing. haha.

[thingstodo]

Hmm ...

- you're testing your 1000A amp boards at high current to check on a soldering technique ...
- and you are working on the FOC control for the AC controller boards
- then you started a solar project
- and you were bored, so you decided to design a battery charger as well?

A guy could get tired just READING about what you're doing!

[MPaulHolmes]

haha ya. I'm a bit of a scatterbrain. That's how I ended up with a 1.2 GPA in high school. I only have space to set up one thing at a time, and the solar charger/pure sine wave inverter are by far the easiest to get working. So, I figured that since the 3 phase controller will blow up several sets of igbts until it's working, I figured it's best to get the other stuff working first, since each controller type is doing double duty.