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The Zilla comes in two current ratings and up to three voltage ratings:
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Zilla Controller Model Z2K-HV (Cour tesy of Caf Electric, LLC)
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The Z1K-LV is the lowest cost unit While it regulates up to 1,000 amps of motor current to run on lead-acid battery packs of 72 to 156 volts, this unit is more than twice as powerful as the common type of controllers for most normal car conversions Because Caf Electric wants people to convert cars to have affordable options, they use the sales of higher voltage controllers to partially subsidize production of the Z1K-LV units This keeps the amount of these units delayed for a reason The Z1K-HV can regulate up to 1,000 amps of motor current and run on leadacid battery packs of 72 to 300 volts nominal This unit in a typical car with a shifting transmission and a powerful battery pack of at least 200 volts will result
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Maximum nominal input voltage range for Lead-Acid batteries: 72 to 348 volts Absolute maximum fully loaded input voltage range: 36 to 400 volt s* Maximum motor cur rent at 50 C heat sink temperature: 2000 Amps for Z2K, 1000 Amps for Z1K Maximum Batter y Current at 200V: 1900 Amps for Z2K, 950 Amps for Z1K Maximum Batter y Current at 300V: 1770 Amps for Z2K, 885 Amps for Z1K Maximum Batter y Current at 400V: 1600 Amps for Z2K, 800 Amps for Z1K Continuous motor cur rent @ 50 C coolant temp and 100% Duty Cycle: o ver 600 Amps for Z2K, 300 Amps for Z1K Peak Power: 640,000 W atts for Z2K, 320,000 W atts for Z1K PWM frequency 157 kHz Power devices IGBT Voltage Drop: <19 volts at maximum cur rent
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* At this time we are suggesting not exceeding 375 volts on the EHV models; we hope to bring that back up to 400 volts with further testing
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Table 7-1 Zilla Specifications
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in a very quick EV These units receive priority in production and so will be built quicker than the Z1K-LV units If you are in a rush to get a controller, you might consider one of these even if you are running a lower voltage car The Z2K is the unit for those looking for the most power available It regulates up to 2,000 amps of motor current while running off a lead-acid battery pack of 72 to 300 volts nominal (348V for the EHV model) This model is used in all the world s quickest EVs There is nothing wrong with running a Z2K in a street car, and many people do it, but be sure to turn it down first or you will just end up breaking other parts of the car! There are also the Z1K and Z2K HV models, which can be ordered as an EHV model These give a nominal input voltage rating of 348 volts for those truly wishing to push the limits of sanity in their EV These Zilla controllers are so powerful that the batteries have trouble supplying the high currents of these controllers, and motors can get damaged by them as well That is why it helps to have appropriate engineers to assist you with the formulas needed to calculate proper voltage limits While the book is a great resource, be sure to set the current limits to reasonable values for your setup before testing With the new highly capable batteries available today such as a 32-series automotive class lithium ion cell from A123 Systems are more energy dense and able to deliver speed and range Combine A123 and the Zilla controller and you will have a full performance ride of your life (Source: wwwA123Systemscom)
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