Using a Castle ICE Aircraft Controller in FE boats

[longballlumber]

Ok folks, as promised I now have pictures of the various controllers that I have converted to water cooling.

This first one is a Phoenix ICE Lite 200 - I had 4 bars made that were epoxied on using the Arctic Silver Thermal Epoxy. At the time I was trying to get as small package space as possible for a rigger. After it was all said and done, this was still too thick.

[longballlumber]

This next one, I started with exactly the same controller as stated above the Phoenix ICE Lite 200

Only this time I tried getting the cooling tubes directly on the bus board (I think that's what it is) using the same epoxy as stated above Arctic Silver Thermal Epoxy

This was a little more tricky because I had to do some creative bending of the tube to avoid other components of the controller that wouldn't allow simple straight tubes.

[montymike]

Nice!

[longballlumber]

For this next one I used the most recent updated model of controller from Castle. In my opinion this creates a VERY nice package. I used the Phoenix Edge Lite 200 Unlike the previous model they put a short aluminum extrusion on the Lite version. I am sure this is to provide a small amount of heat transfer. What's nice on the 200 model is there is just enough room to tuck a couple of cooling tubes in the corners of the aluminum extrusion. This keeps the package same even though you've added water cooling. I also like this because I don't need to get the Arctic Silver Thermal Epoxy near the board.

[olwarbirds]

Mike, nicely done. Do you have to use a pistix for these to work in our application ?

[longballlumber]

Last but not least and because I liked the 200 amp version so well, I converted a Phoenix Edge Lite 100.

This was a little different because there wasn't enough room to put the tube inside of the extrusion, so I simply put them on the out side of the case. I think this is a nice little application.

[longballlumber]

Mike, nicely done. Do you have to use a pistix for these to work in our application ?

That is one of the caveat's with these... I am unsure of the success rate of others, but I already use a "stick" style Futaba radio's. It's what I grew up using and still prefer to use them when racing boats. I seem to recall Jay saying that he's gotten it to work with one of his "wheel" style radios, but I can't be 100% sure. Tyler is another one. I am not sure if he is using a stick or wheel radio. Perhaps those guys can chime in.

Later,
Mike

[olwarbirds]

Tks Mike, I hope so. I have a new hydro I want to run today if I can get it working... DJ

[ray schrauwen]

Yes Jay knows how to set up his radio for the air esc's, not sure which radio??

Mike: So you just take the heat off the bus bars like Castle does with the green casings. The ones with green casings XL2, etc.. have a non conductive material on one side so it doesn't short out across the case.

So it's o.k. to just cool the buss bars and not FETs directly.

[longballlumber]

Yes Jay knows how to set up his radio for the air esc's, not sure which radio??

Mike: So you just take the heat off the bus bars like Castle does with the green casings. The ones with green casings XL2, etc.. have a non conductive material on one side so it doesn't short out across the case.

So it's o.k. to just cool the buss bars and not FETs directly.

Ray,

I have no way of determining if my methods are the "best" way or not. Like you I looked at the hydra line of controllers and noticed they didn't do a very good job of making contact with the actual FET's. The problem with making contact with both the bus bars and the FET's is the height of them are very inconstant.

With all of that being said, my seem to be working fine. However, they haven't been "pushed" in extreme conditions.

Later,
Mike

[Fluid]

The easy way to connect the aircraft controllers to the receiver is with a PiStix, but Spektrum transmitters can be programmed to work without one. Some claim they have used Futabas but I have never tried it. Here are the settings on the Spektrum which work for me:

DX3S
Throttle - B 100 F 100
SubTrim - B 100
ThrottleTrim - B 50

DX3R PRO
Throttle - H 100 L 150
SubTrim - TH 100L
ThrottleTrim - minus 100


The FETs and the bars are very close to the same height and the extrusions With the thermal grease I use cover them both, or at least part of the FETs. The factory extrusions on the Hydras and non-ICE controllers do this, but not every FET is covered.



.

[olwarbirds]

Jay, tks ..that worked...I did have to set my reverse trim a bit further back but its all good now..again tks bud... DJ

[ray schrauwen]

What does the "B" and the "F" denote for these radios? Just so I might try it on my Chinese cheepo radio.??

The easy way to connect the aircraft controllers to the receiver is with a PiStix, but Spektrum transmitters can be programmed to work without one. Some claim they have used Futabas but I have never tried it. Here are the settings on the Spektrum which work for me:

DX3S
Throttle - B 100 F 100
SubTrim - B 100
ThrottleTrim - B 50

DX3R PRO
Throttle - H 100 L 150
SubTrim - TH 100L
ThrottleTrim - minus 100


The FETs and the bars are very close to the same height and the extrusions With the thermal grease I use cover them both, or at least part of the FETs. The factory extrusions on the Hydras and non-ICE controllers do this, but not every FET is covered.



.

The FETs are close in height but, not that close, about 0.030" higher thant the bus. The top heat sink on the XL2 is machined so it touches the bus and FETs but, the bottom case heatsink does not touch the fets, just the bus.

I'll take pics of the xl2 innards later.

[Fluid]

On the ICE controllers the FETs are just a few thousandths lower than the bars.






.

[olwarbirds]

Ray, forward and back/reverse.....