Last night was a smokeless night. After fixing the controller we went on to use a current limited power supply and later on a fused 48V pack.
After an initial power up with the power supply - limited to 30V we came back to the dreadful 48 pack. This time a 5A fuse was added
Everything worked properly this time using the same type of components that failed last time. This strengthens my theory that the short circuit I found from Vbatt+ to a high side FET gate lead to the 4th of July effect.
One change I make was to increase all gate series resistors from 10 Ohm to 100 Ohm in order to decrease dI/dT stress on the FETs.
Here are some scope PICs I took:
Low side FET turn on time:
High side FET gate (Ground referenced)
Phase Voltage (Ground referenced)
Also some Vids of the setup in work:http://www.youtube.com/watch?v=yNC_Ar12cfwhttp://www.youtube.com/watch?v=cNmBVIWDO1Q
A Lot of work ahead...