100amp power module wanted

[hank]

Looking for a penny and giles 100amp power module

[rover220]

Which system?

[hank]

pilot + on a quickie f55

[Burgerman]

The actual components of the 50, 80 and 100 are the same. Only the firmware seems to be different. Well from my eyes and a magnifying glass. So if you have a 50 or a 80A one it *should* be possible to modify it. But having said that I have no idea how to do this.

[hank]

John.
Did you say you used a 100amp penny and giles pilot plus controller, from a pride 850 storm? to your bm1-bm2 chairs.
Looking for one. Its got a 80amp in now.

[Burgerman]

They were used on many chairs. Usually the faster 7 or 8mph ones.

I am not exactly sure what mine are from. One ebay, one direct from PG Drives new, one donated.

[rustyjames]

Some Quickie 646SE and 222SE use the 100Amp controller. This would be PG Pilot Plus. Here's the controller number from Sunrise Medical:

910062 RMT PRG PILOT+ 80/100A S646 S646SE (NON HD) 250 lbs 8.5 mph

[Burgerman]

For what its worth, the 120A Rnet and the 120A DX2 modules are really just exactly the same, with a short term boost allowed by software/firmware. They look the same as the Pilot plus and PM90 almost on the inside. The Rnet is really a 100A unit, and the DX2 is really 90A.

Heat is the problem.

These all use little to no heat sinking. And uses 8 output power MOSFETS.

The roboteq for e.g. uses 32 MOSFETS, so 4x better, and pretty good heat sinking bolted to a finned casing. And at double the volts.

[LROBBINS]

John,

Don't know about P&G, but heat-sinking in the Dynamic DX PMs is pretty good. They use a finned, die-cast aluminum case and conductive greased strong spring-finger strips directly between the MOSFETS and case. Older and fewer MOSFETS than the Roboteq, so yes, decidedly heat-limited. Ciao, Lenny

[hank]

Would fans and a few drilled holes in cases help for heatsink problems.

[Burgerman]

That's it. Bit of foam rubber pushes this together...

No sink at all.

Drilling holes will let in water or dirt.

[hank]

Thanks John.
I see what you mean now from picture.Poor idea for heatsink.No wonder they suffer with heat.

[LROBBINS]

Grrr. I remember a picture like that which you posted to illustrate the "sponge rubber" used to get electrical contact. So the only heat sinking is the connector tabs, held in contact by some plastic foam. What a piss-poor design. The dynamic not only has good heat sinking, but all connectors are SOLDERED to the board.

[Burgerman]

Quite!

The dynamic I haven't seen.

The Roboteq has a sub 3mOhm "on" resistance. So very little heat to get rid of. From 32 Mosfets too. According to the site. instead of 8. And these are bolted solidly to the finned alloy casing. So it should be at least 4 times better for hard work!

Was going to fit a fan. But it gets warm to the touch in light use. It doesn't seem possible to make it get any hotter as you end up going way too fast and its way too hard trying! Maybe on the beach at speed.

[LROBBINS]

Here's a snapshot of an old DX60 that I've been cannibalizing - including getting the motor/brake connectors by cutting off the pieces of board where they were attached. There are 16 MOSFETS, but I haven't cleaned off the grease to see the markings as I never intend to use them.

DX60b.JPG (104.82 KiB) Viewed 10646 times

[hank]

What amp is this one in your above pic LROBBINS ?

[Burgerman]

DX60?

[hank]

60amp?

[Burgerman]

DX60b.JPG (104.82 KiB) Viewed 5 times

Clue...

[LROBBINS]

Yes, that is a 60Amp unit, though the guts are at least basically the same on the 90. I haven't gone through them component by component to see what's actually different between the 60 and 90, but if it's just in software it requires more than OEM access. I have an OEM dongle, but know that an Engineering dongle only for within-Dynamic company use also exists.
Ciao,
Lenny

[Burgerman]

I suspect the 120A units are the same. Software short term blip to 120 allowed for marketing.

[hank]

John the slotted holes in back of PM that go through to terminal area.
Are they not to be covered when fitting to a large alloy plate as on you BM2 clone for cooling.?

[Burgerman]

No even when bolted on to a flat metal plate they still flow air. You can fit a cooling fan too if you want. And turn up the roll-back temperature a little. Default is 55C mine has been set to 70C for 16 years and no problems...

[hank]

Thanks for Advice on Holes.
Would there be any gain in using heatsink paste, Between both surfaces of PM to alloy plate when fixed together.

[Burgerman]

Not really, the REAL problem is inside. They are not heat-sinked, but all the heat goes to the input/output terminals amazingly. Remove a cover, take a look. Best bet is a fan, to blow on the whole thing.

[hank]

Been looking on overclockers site.
Thinking of fitting two 80mm 12v fans.

[Burgerman]

It will help.

[hank]

John.
Fitted a pair of 80mm fans to cool PM. Looking how the PM has air flow in casing only from circuit would you wire to suck or blow air from fans.
Would some sort of temp sensor wired up work.? Think it would be hard to control the heat through PM. Or would they be better to run constant.
Wired through a switch on/off.

[Burgerman]

You can get thermo switches cheaply, say 35 / 45 degrees. And blow!

http://www.aliexpress.com/item/10pcs-pa ... 45296.html stick it inside the case or on the board, or direct to a power mosfet with epoxy. or a similar product.

I have 2 65C ones stuck to my motors on my BM3 to turn on a tiny buzzer if they get too hot.

If that happens we will water cool.

[hank]

Thanks.