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800V 125kW SiC Dual-Side Water-Cooled Controller

The module is a flexible, modular power quality product designed for harmonic suppression, power factor correction, and three-phase balance.

Rated capacity: 30A/50A/75A/100A/150A/200A
Rated input: 200/400/480/690/800V AC
Grid frequency: 50/60 Hz ± 10%
Filter range: 2 to 50 orders
Installation types: wall-mounted, rack-mounted, upright
Power grid configuration: 3P3W, 3P4W

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Product Description

Product Overview

With the advancement of semiconductor technology, SiC power devices have now become a key development direction for third-generation semiconductors both domestically and internationally. Compared with Si power devices, SiC devices exhibit superior characteristics such as high temperature, high voltage, and high frequency operation. In this project, by leveraging advanced motor simulation (PowerHil) technology and rapid prototyping platforms based on FPGAs, we can easily validate various SiC devices and modules, facilitating comprehensive research into the performance characteristics of SiC power devices.

This project involves developing a driver for power devices based on a SiC double-sided water-cooled packaging configuration.

Project	Assessment indicators
DC bus voltage	>800V
Controller rated power	≥125Kw
Controller peak power	≥250Kw
Maximum efficiency of the controller	≥99% @ 500V
The maximum switching frequency of the controller	≥20kHz
Maximum output current of the controller	≥400 Arms @ 120 s, 600 Vdc
Power semiconductor	SiC devices with a double-sided liquid-cooling package configuration
Controller operating ambient temperature	-40℃~85℃
Maximum operating frequency of the controller	≥1000Hz
Control the power supply range	12V (8V—18V)
Power density	≥30 kW/L

The operating principle of the controller

Electrical schematic diagram

The primary task of a three-phase SiC motor controller is to convert the direct current (DC) output from the battery pack into three-phase alternating current (AC) with adjustable frequency and amplitude, thereby driving either a permanent-magnet synchronous motor (PMSM) or an induction motor.

DC Link: The DC power supplied by the battery is first stabilized and filtered through busbar capacitors to absorb voltage fluctuations during switching operations.
Three-phase inverter bridge: This is the core of the controller, consisting of three sets (a total of 6) of SiC MOSFETs. Each set includes an upper bridge arm and a lower bridge arm, which respectively control the current flow to the motor’s U, V, and W phases.
The role of SiC MOSFETs: As a high-speed electronic switch, it rapidly “turns on” and “turns off,” chopping the DC current into a sequence of pulses.

Technical Specifications

Name	Specification Parameters
Motor controller model	CE-800/400-X0HS-TZ/SC-GC
Rated input voltage	600Vdc
Maximum input voltage	800Vdc
Applicable motor	Permanent magnet synchronous motor or AC induction motor
Rated power (kW)	125kW
Peak power (kVA)	250kW
Rated output current	250A
Peak output current	≥400 Arms @ 120 s, 600 Vdc
External power supply input voltage range	10–32V, typical value 12V/2A
Controller Efficiency at Rated Conditions (%)	≥99%
Output frequency range	0.00–1200 Hz
External dimensions (mm)	296 mm × 195 mm × 117 mm
Weight (kg)	About 7.5 kg
Cooling method	Liquid cooling
Water flow rate	≥15 L/min
Protection level	IP67
Working environment temperature	-40℃ to +105℃
Encoder type	Rotary transformer
Control method	Torque or speed
Torque response time	Zero torque to rated torque <100 ms
Torque control accuracy	±5% of rated torque
Rotational speed control accuracy	≤±1%
High-voltage input terminal	+、-	Automotive connector, two-core
High-voltage output terminal	U, V, W	Automotive connector, three-core
Motor temperature sensor	Pt100 (default); can also be hardware-configured as Pt1000.
Protection function	Overtemperature of the controller, overtemperature of the motor, overload, short circuit, overcurrent, overvoltage, undervoltage, and others.

External dimensions (optional)

Product Features

Supports multiple communication protocols (CAN, RS485, ModBus)
The drive scheme employs a three-phase full-bridge inverter, with each U, V, and W bridge arm using one 800A SiC power device, capable of delivering a phase current of no less than 400A.
Use upper and lower water-cooling plates to clamp the double-sided water-cooled SiC device.
The gate driver uses a Rohm driver IC, which offers sufficient driving capability and a 3750Vrms isolation withstand voltage.
The output side has three Hall sensors that sample the U, V, and W phase currents.
One Hall sensor on the input side, sampling DC current.
A passive discharge resistor is installed inside the enclosure.