MAD FOC IGBT 160A 80~510V Drone ESC

Overview

The MAD FOC IGBT 160A ESC is a high-performance Electronic Speed Controller (ESC) designed for UAVs, underwater propellers, electric vehicles, and industrial applications. It features an IGBT three-phase full-bridge inverter topology with a maximum peak output current of 320A, ensuring high efficiency and stable operation.

This sensor-less FOC ESC provides precise motor control, increased efficiency, and smooth performance. With an 80-510V DC input voltage range, overvoltage and undervoltage protection, and external forced air cooling, this ESC is built for demanding environments where reliability is essential.

Key Features

• Wide Input Voltage Range: DC80V to DC510V, with built-in overvoltage and undervoltage protection.
• High Power Handling: Supports a continuous output current of 160A, with a peak output of 320A.
• Advanced Control Algorithm: Sensor-less Field-Oriented Control (FOC) for precise and efficient motor management.
• High Frequency Modulation: SVPWM with a 10kHz carrier frequency, optimizing efficiency and power delivery.
• Versatile Compatibility: Supports PPM/PWM input signals with frequency support from 50Hz to 400Hz.
• Multiple Communication Interfaces: TTL232 and CAN for real-time monitoring of voltage, current, speed, and temperature.
• Robust Cooling System: External forced air cooling to prevent overheating and ensure long-term reliability.
• Comprehensive Protection Mechanisms:
  • Overvoltage & Undervoltage protection to prevent system failure.
  • Throttle detection to ensure safe operation.
  • Overtemperature protection with automatic power adjustment at 90°C and 100°C.
  • Sensor zero-point detection for accurate phase current management.
• IP54 Protection Rating: Dust and water resistance, making it suitable for rugged environments.

Specifications

Parameter	Value
Name	MAD FOC IGBT 160A 80-510V ESC
Application	UAV, Underwater Propeller ESC
Input Voltage	DC80V - DC510V
Input Current	≤160A (with current limitation protection)
Output Current	≤320A (with constant power protection)
Output Frequency	≤1000Hz (adjustable)
Modulation Mode	SVPWM, Carrier Frequency: 10kHz
Control Mode	Sensor-less FOC
Efficiency	≥98%
Controller Interface	PPM/PWM (50Hz - 400Hz)
Communication Interface	TTL232, CAN
Weight	≤3.0kg
Dimensions	257mm × 155mm × 90.5mm
Cooling Mode	External Forced Air Cooling
Operating Temperature	-20°C to 90°C (with temp protection)
Protection Degree	IP54

Protection Mechanisms

1. Undervoltage Protection

• If the input voltage drops below the threshold, the ESC enters protection mode and stops output.
• The system resumes operation after a 5-second reset.

2. Overvoltage Protection

• If the input voltage exceeds the limit while idle, the ESC enters protection mode.
• If the motor is running, the ESC triggers an alarm but remains active.

3. Throttle Detection

• The ESC checks for throttle loss and non-return to zero detection.
• Audible alarms activate if an issue is detected.

4. Sensor Zero-Point Detection

• The system automatically detects and calibrates phase current zero points at startup.

5. Overtemperature Protection

• At 90°C, the ESC reduces input current to prevent overheating.
• At 100°C, the ESC limits output throttle for protection.

6. Communication Protocol

• Utilizes IG-UART_V1.2 at 19200 baud rate, broadcasting real-time data every 255ms.

Control Signal Standard

• Compatible with aircraft remote controllers.
• 50Hz frequency cycle, with high-level times between 1150 to 1950µs.
• Optically isolated telecontrol signals for safety and interference protection.

Throttle Calibration Steps

1. Connect the ESC PWM signal to the receiver.
2. Turn on the remote control and set the maximum throttle position.
3. Power on the ESC and listen for confirmation tones.
4. Set the throttle rocker to the preset starting position.
5. Listen for calibration tones confirming successful configuration.
6. Turn off power to save settings.

Connection Description

• Power Cord: Positive & Negative Input.
• Throttle Signal Cable: PPM/PWM signal input.
• Serial Communication Cable: TTL data transmission.
• CAN Communication Cable: CAN-H and CAN-L signals.

Compatibility

• Compatible with all DC Brushless Motors.
• Custom debugging available for motors with specific requirements.

Recommended Motors & Propellers

ESC Model	Motor	Voltage	Propeller
AMPX 160A FOC	M90C60 KV10	400V	63X22 / 72X25

Dimension Drawing

• Overall size: 257mm x 155mm x 90.5mm.
• Detailed technical diagrams available.