Controller circuit for Hilden Brandt motor needed..

[boxofsparks]

Shruggedatl
Sorry consider yourself Flamed
Jack has been VERY open about this project and needs the money but is NOT fishing for it IMHO
I have had many conversations and contacts with Jack and helped on some material, I read people very well and his is one of our best chances at OU. IMHO
Jack Thanks for all of your work and disclosure
PS Honk your Great thanks for the help
Jon

[shruggedatlas]

Shruggedatl
Sorry consider yourself Flamed
Jack has been VERY open about this project and needs the money but is NOT fishing for it IMHO
I have had many conversations and contacts with Jack and helped on some material, I read people very well and his is one of our best chances at OU. IMHO
Jack Thanks for all of your work and disclosure
PS Honk your Great thanks for the help
Jon

I may be wrong and this may all be well-intentioned, and certainly Jack is under no obligation to disclose more than he has.  COP of over 6 just sounds too good to be true.  Everyone else would kill for 1.00000001.

[Honk]

Well, soon we might know for sure if the reported COP of 6.21 is true or not.
I have finished examining the broken controller and I have found the most plausible cause of the failure.

The BEMF recycling unit Toroid must have fallen off in some extent on its way to Jack. Perhaps just one of the wires.
I could see that all semiconductors in the BEMF recycling unit was OK but they would be broken if the error started here.
But one of the 1200V IGBT output phase transistors was broken and this caused a short circuit that fried the AC-DC converter.

I believe that the BEMF recycling unit could not return any BEMF and this caused the Valve return voltage to shoot higher than 1200V.
When this happenend one of the IGBT:s finally broke down and smoked the converter.
I tested the current limit of the converter before I shipped it to Jack but there was no time to perform the more time consuming short circuit tests.
This is a high voltage output AC-DC converter and performing the short circuit tests require lot's of patience to repair it at breakdowns.
I'm not sure if I have the time right now to tune in this feature. Perhaps it's better just to repair it and make sure it's working fine and
then ship it back to Jack. I believe he's eager to test it again as he noticed the motor/controller working really great before breakdown.

But I will enhance the BEMF recycling capacity as well, just to be on the safe side.
And this time I'll use a ton of glue to prevent another shipping failure.

[Honk]

An update:

A have fixed the broken controller and it's back into full operating mode.

Two 1200V IGBT, one 550V 20Amp mosfet, and two 150V 55Amp mosfets were smoked.

I glued the coils last time before shipping it to Jack but this time I have really used a lot of glue
on all coils and other big components to prevent this from happening once again.

I lowered the BEMF level from 1150V to 900V in order to use a better and lower Rdson 1000V mosfet.
This new mosfet can handle a lot higher BEMF recycling power without overheating.
And the lower BEMF level at 900V gives a little more headroom on the 1200V IGBT:s.
Later this year St Micro will launch a 1200V low Rdson mosfet. That will fit perfectly in this controller.

Tests will continue during this weekend. If everything seems OK I'll return it to Jack on monday.

[Honk]

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