24 Mosfet Controller XJC8b116 microchip Information Thread

[steveo]

Hey Everyone,

I would like to share a new controller that is in testing stage, Please Don't ask me how to purchase or the cost of the controller yet. I will notify everyone once i will have them avaliable in stock; I am looking to keep these as diy kits for everyone to give the best cost possible to the buyers; however depending on the demand of the customers; I will look to assemble or partaily assemble the kits to make it easyier for those with little to no soldering skills.



-these controllers will come with i believe with the new XJC8b116 Microchip (will have infineon XC846 all feature but stonger than XC846)
-these controller will be fully programable just like the 18 mosfet controllers
-These controllers will be even more robust then its sister 18 mosfet controller est 150amps no problem!

The kits i would like to sell will include (ill describe best i can)
-Phase wires/power wires
-C/a connector
-All pigtails/throttle/hall sensor connector etc
-(all the rest of the parts you see in the picture; that pcb isn't populated yet.. I'll try to get a photo of it fully populated)

If you are interested in purchasing; pm me privatly & i will add your name to a list of interested buyers; & prior to making my order i will be asking for payment to cover my costs

I will be getting 2 sample controllers to build and test up to 150v with the irfb4115 mosfets, this controller combined with my 150v a123 battery (under construction) with my x5306 motor ... should be very quick; maybe i'll install a jet pack on the back to give me an even bigger boost LOL

*****************************************************************************************************************************************************************
Programable USB Software Download (added 2010/01/30)
-extract the "support" folder to ----> C:\WINDOWS\system32
-the main suppot folder, extract and run the program!, the processer type is EB224

A ENGLISH COPY WILL FOLLOW!!!!!


18 MOSFET SOFTWARE SCREENY

24 MOSFET SOFTWARE SCREENY




IF YOU WISH TO PURCHASE THIS CONTROLLER GO TO THE GROUP BUY THREAD: http://endless-sphere.com/forums/viewto ... =9&t=15742

One of the controllers i built below...

thanks
-steveo

[steveo]

What are your thoughts guys?

Any room for improvements?

-steveo

[Vanquizor]

If you build it they will come....


I'd be happy to sample the high volt version.

[Doctorbass]

Ah haa!.. TRUE POWER !!

Excellent news Steveo!

-Doctorbass setup reached 15kW (measured)
-Method setup reached 20kW ( apparently)
-Steveo setup will reache.. ??? 30kW?

Man.. that's 40hp ! You will need 2x one inch wide steel
torque arm!!

let see what it shold look like about power:

According to Methods, the 18 mosfet can go up tp 300A burst assuming that's at 88V it's 26kW

The 24 mosfets with an higher IR ( 4115 have 11mohm instead of 4110 with 4 mohm) could do (4/11) x 300A x (24/18) = 145A burst

and 145A at 150VDC.. let say 135VDC with sag = 20kW

on a 20inch wheel that's equivalent of 350pounds trust... so... coul can twist seriously the axel..

or if your tire could stick to it...you could climb a vertical wall with you on the ebike no prob...

If that 5306 cold be wired in serie parallel to acheive 5303 or 5306 that would be very nice!

Doc

[steveo]

could anyone predict the top speed of my x5306 @ 150v & at 133v?

At 100v .. freewheel speed on 20" is about 60km/h

I found that the freewheel speed & the on the road speed are very close; maybe its to due with the low winding motor

ex ... 47.5km freewheel .. and i could swear i hit 44-45km/h on road lol... really good i think !! .. and motor stays super cool.

-steveo

[steveo]

80km/h @ 133v lol ...

it will be neck breaking acceleration i bet ..

I think 75km/h - 80km/h is a top speed... fast .. but not to fast!.....

What do you think range will be like with 4p of a123...

lets say run the pack up to 8ah... I say 25km/h .. if i ride it relativly easy on the throttle..

probably 10km if i'm killing in on a circuit LOL

I'm using .032" copper sheet to build my a123 pack & 8 AWG wire to link 7 of my 6s packs for 138.6v nominal...

-steveo

[Mike1]

Steveo, I think maybe you should put that jet pack on the front to use as a brake

[Doctorbass]

I have 11 Dewalts pack sitting in my lab

I wonder if i should try a fast charge 48V pack with charger included..

I mean 15-20 minutes for full charge!

a 48V 9.2Ah should be ok

I have a cahrger capable of 37A 51V continuous out of an 120Vac outlet !

16s4p...

or should i use all them to make my 100 to 136V upgrade on my fast speed record ebike ! 10s4p

hmmm..

Steveo.. your 5306 at 150VDC will be VERY impressive!

That motor heat volt.. not amp!!

it has so much torque than no load and full load speed are like the same... I feel that on my 5305 so with a 5306... hmmm

Doc

Doc

[Doctorbass]

Steveo.. Why not using the »FDP2532 instead of the 4115??

Their miliohm is a bit lower= more current!

see the discussion about that: http://endless-sphere.com/forums/viewtopic.php?f=14&t=14013&p=211342&hilit=fdp2532#p211342


Credit to Camlight:
the Rds-on of each FET at 125C as this is what the actual Rds will be as the FET heats up. Here are the numberss:

IRFB4110 = 8.3 mOhms
IRFB4115 = 23.1 mOhms
IRFB4568 = 12.4 mOhms
FDP2532 = 19.2 mOhms
IXFH160N15T = 32.0 mOhms



Remember that ?: http://endless-sphere.com/forums/viewtopic.php?f=2&t=8728&hilit=150vdc


Doc

[steveo]

Hey Doc,

are you sure that # is right for the irfb4115?; I remember bob say it is lower then the fdp2532 mosfet;

also; I've noticed the quality of the 4115 is MUCH better (identicall to the qualify of the irfb4110) then the fdp2532 mosfet;


as per fechters post


IRFB4115, apparently the next up from the 4110.
150v, 104A, 9.3mOhm and comes in a TO-220AB package that fits most controllers.

maybe the resistance is much higher once they are very hot?

-steveo

[steveo]

Hey

Nevermind, your right doc ..

i'm kinda dissapointed; the qualify fo the irfb4115 is better!!!!

-steveo

[ZapPat]

Hey Doc,

are you sure that # is right for the irfb4115?; I remember bob say it is lower then the fdp2532 mosfet;

also; I've noticed the quality of the 4115 is MUCH better (identicall to the qualify of the irfb4110) then the fdp2532 mosfet;


as per fechters post


IRFB4115, apparently the next up from the 4110.
150v, 104A, 9.3mOhm and comes in a TO-220AB package that fits most controllers.

maybe the resistance is much higher once they are very hot?

-steveo

The FDP2532 has much higher resistance even when hot compared to the IR4115, so stick with the IR part, Steveo.

Doc - I understand why you said this though, because that second link you posted has some confused numbers for the FDP device. The right ones are 32mohms@125oC and 0.48oC/W in the datasheet I have. The FDP2532 is a pretty old tech MOSFET, so it isn't surprising that it doesn't hold up against the IR4115.

And remember Steveo to use a really thin insulation layer under your FETs, like kapton (without the sticky layer is best).

Any chance of pics of a 24 FET board... pretty please?

[Doctorbass]

Sorry Steveo.. It seem that the FDP2532 spec i found aren't right..

thanks Zappat for clarifying that

The one i ordered at digikey say:

2532: Rds On (Max) @ Id, Vgs 16 mOhm @ 33A, 10V
4115: Rds On (Max) @ Id, Vgs 11 mOhm @ 62A, 10V


Here is teh link:
2532:
http://search.digikey.com/scripts/DkSearch/dksus.dll?lang=en&site=US&WT.z_homepage_link=hp_go_button&KeyWords=fdp2532
4115:
http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=IRFB4115PBF-ND

i'll ask to camlight abot that confusion..

doc

[steveo]

wohoo.. i was right .. maybe

i remember 4115 was 11mohms ... the fdp2532 16mohms .. it makes sence to me ..

i'm glad to hear i'm right on this .. the quality of the irfb4115 is exaclty like the irfb4110... alot Better!!!!!

I've requested better photos of everything.. as soon as i know .. everyone here will also!!

-steveo

[CamLight]

Aaaarrgghhh...I don't remember how I derived that lower Rds-on for the 2532, but I was wrong. Thanks for catching that ZapPat!

FDB/FDP/FDI2532 Rds-on (max) at 125C Tjunction = about 32mOhm
IRFB4115 Rds-on (max) at 125C Tjunction = about 23mOhm

Their thermal resistance specs are fairly close so you can stick to the Rds-on numbers and the capacitances and gate charges to compare heating in a controller.

[steveo]

anyone know the best place to purchase some irfb4115's?

I've checked digi key/avnet/ and a few other places .. either the prices are to high or not enough stock..

i really want to avoid ordering from ir they only offer 50$ overnight shipping ... which is bs in my opinion..

-steveo

[CamLight]

You might have to go to multiple sources. None of the places with stock (that I found) have more than a couple hundred on hand. But, there are about 700 total available from distributors. Shipping would get interesting if you needed all overnight though.

[ZapPat]

Steveo:

65pcs stock at digikey.ca
160pcs stock at digikey.ca

They are about 2.50$CAD ea for 100pcs, and shipping would be fast and free. The "G" variant is just as good as the regular one, so you choose.

[steveo]

Are you excited?

I am ...



i just got word .. that i will have 200v capasitors installed from factory .... fingers crossed!!!

The power supply portion of the controller will be able to be operated from 86v - 200v ... ..

the resistors on the unit would need to disipate 11watts

-steveo

[liveforphysics]

Good for you Steveo

I saw a really impressive specsheet for a 170v TO-220 fet the other day while component browsing *EDIT* I was mistaken, it was TO-247 package: ( *EDIT* . It might be perfect for this application to make a Kelly alternative motorcycle voltage controller. Or an E-bike controller for guys who enjoy a little speed.

Here are some of the best choices I could find for options in the 150-200v range that fit your package needs:

http://www.irf.com/product-info/datashe ... 20dpbf.pdf

And a couple more.

IXTV130N15T
Description MOSFET N-CH 150V 130A PLUS220


http://www.infineon.com/dgdl/IPP075N15N ... edead96fab

[markcycle]

Are you excited?

I am ...



i just got word .. that i will have 200v capasitors installed from factory .... fingers crossed!!!

The power supply portion of the controller will be able to be operated from 86v - 200v ... ..

the resistors on the unit would need to disipate 11watts

-steveo

I am
Got the Dyno ready to test

[steveo]

What are everyones thoughts on the new to-220 package?

IXTV130N15T
Description MOSFET N-CH 150V 130A PLUS220

It looks good ... This it will outpreform the irfb4115

-steveo

[ZapPat]

http://www.infineon.com/dgdl/IPP075N15N3+G_Rev2.03.pdf?folderId=db3a3043156fd5730115939eb6b506db&fileId=db3a30431b0626df011b25edead96fab

That one looks real good for a 150V part! 7.2mohms, and very good gate charge caracteristics.

But... those third generation optimos FETs from infinion are very hard to source it seems to me. Maybe they are too new yet, because a couple months ago I looked for both the 60V and 100V versions and could not find any places selling them. The superior gate charge caracteristics might well be useless when these FETs are put in a "standard" controller design, but they look pretty good otherwise anyways... and I guess that they may well switch just a bit faster than the IRFB4115 too, helping a little bit with PWM efficiency.

[steveo]

Hey everyone,

just a quick update, I will be able to have the kits come with silicone wire 10 gauge!



-steveo

[Doctorbass]

Hey everyone,

just a quick update, I will be able to have the kits come with silicone wire 10 gauge!



-steveo

Great! I've also bought 5 meters of black and red 10 gauge wire at hobbyking. Excellent quality!