Paul & Sabrina's cheap DIY 144v motor controller

[isaac_alaska]

I have a 1000 amp controller in my snowmachine, and it works incredibly well. mine is a little more expensive than the kits that paul sells though because i used an SBE 1000uF DC link film capacitor (~$200) and 3 big IGBT modules (between 75 and 300 each i think, depending on where you buy them) instead of TO-247 packages. it uses Adam's driver board and laminated bus plates, and one of paul's old logic boards.

It certainly gets the job done, and the components in it are Rated to 600 volts.

[sawickm]

I know DC link film capacitors work well with the IGBT controllers. Does anyone one know if DC link film capacitors could replace the electrolytic capacitors used on the MOSFET controllers?

-Mark

[isaac_alaska]

definitely, but you would need to build a new power board to mount all of the MOSFETS and diodes to.

[AviatorBJP]

Very cool Isaac!

So you used the logic-board from the 500 amp controller with a different power-board? Or is it a different logic board entirely?

I have found a couple IGBT modules that I was interested in using in my controller. Using the large film capacitors also helps prevent unequal heating around the power section, so I was considering using those as well.

I am building a mild-mannered commuter car, but I like the idea of using high voltage with a relatively low AH rating on the batteries; taking advantage of Peukert Effect, lower battery side amps, and all that jazz. 600 volts is much higher than I was planning on using, but that's got me thinking now...

[isaac_alaska]

i used the cougar logic board, revision 1a. there weren't very many of them made though. but i think any of the logic boards would work.

600V is the upper limit on the parts, and with switching transients i wouldn't run them probably any higher than 400 volts. above this it gets harder to find chargers, also

[AviatorBJP]

So what do you guys think of this IGBT and this Capacitor being used in the power section of a controller? Keep in mind that I am planning on 192 volts, and maybe, just maybe 300V.

IGBT: FZ600R12KE3 (probably overkill for me)
1200 Volts, 900 Amps
$165.35 from IGBT/MOSFET Modules :: IGBT Modules single :: FZ600R12KE3 - QJYelec.com ----Professional solutions for Power Semiconductor

Capacitor: 944U161K801ABM (might need two?)
800 Volts, 160uF
$62.16 from Digikey. CAP FILM 160UF 800VDC SCREW - 944U161K801ABM

I can provide datasheets if you guys would like them.

[AviatorBJP]

Actually the FZ600R12KE3 datasheet says it is 600A nominal, and 1200A Icrm. So this is actually in the range I was considering anyways.

[flores]

I've read somewhere that you always should devide these numbers by two to be realistic

[AviatorBJP]

And also to be safe. No reason to take an expensive component to the edge of its capabilities.

[isaac_alaska]

You'll need two of those igbt's if you use that one, cause its a single. You need a double so u can use the body diode of the second one. Your Also Better off with film caps from sbe. They are flat and multi-terminal so it's easy to attach to them with a laminated bus. I think 160uf is on the small side... My controller uses 1000 uF which is on the large side.