Product specification

Sealed Al housing

Physical characteristics

• Width: 101 mm
• Height: 13 mm
• Depth: 35 mm
• Weight: 130 g

note

Dimensions with JST JWPF signal connectors, Amass XT60 and MT60 power connectors.

AM controller drawings and 3D models

• 3D model
• Drawing

Mounting

Recommended mounting torque for M3 screws: 1.3 Nm.

Non-sealed Al housing

Physical characteristics

• Width: 101 mm
• Height: 13 mm
• Depth: 35 mm
• Weight: 130 g

note

Dimensions with JST JWPF signal connectors, Amass XT60 and MT60 power connectors.

AM controller drawings and 3D models

• 3D model
• Drawing

Mounting

Recommended mounting torque for M3 screws: 1.3 Nm.

Shrinking tube

warning

This edition is only offered as part of OEM solution and no longer publicly supported.

Physical characteristics

• Width: 89 mm
• Height: 10 mm
• Depth: 35 mm
• Weight: 92 g

Bare board

warning

This edition is only offered as part of OEM solution and no longer publicly supported.

Physical characteristics

• Width: 66 mm
• Height: 9 mm
• Depth: 31 mm
• Weight: 12 g

note

Bare PCB with electrolytic capacitors, without any wiring.

Electrical specification

Input voltage rating

Parameter	0420	0610	0810	1010
Non-operational overvoltage limit	9 -- 40 V DC	9 -- 60 V DC	9 -- 80 V DC	9 -- 100 V DC
Safe voltage range	11 -- 36 V DC	11 -- 55 V DC	11 -- 74 V DC	11 -- 92 V DC
Operating voltage range	12 -- 34 V DC	12 -- 51 V DC	12 -- 68 V DC	12 -- 84 V DC
Li-ion series cell count	8S	12S	16S	20S
Li-ion battery nominal voltage	28.8 V DC	43.2 V DC	57.6 V DC	72 V DC

note

Specifications are valid only in motor mode with field weakening turned off. Contact siliXcon for more information when using motor in generator mode and/or when using field weakening.

Terms explanation:

• The controller delivers maximal current without limitation if the battery voltage is below the Maximum working voltage and above the Minimum working voltage.
• The output current is proportionally limited if the battery voltage is above the Maximum working voltage and below the Full limitation voltage. This is indicated by the "Overvoltage" status.
• The output current is fully limited if the battery voltage is above the Full limitation voltage and below the Critical error voltage (max). This state is indicated by the "Overvoltage" status. The controller automatically recovers if the voltage falls below the Full limitation voltage.
• The controller falls into critical error if the battery voltage exceeds the Critical error voltage (max). The controller can be permanently damaged in this region and does not recover automatically, it needs to be turned OFF and ON again.
• The output current is proportionally limited if the battery voltage is below the Minimum working voltage and above the Threshold voltage. This is indicated by the "Undervoltage" status.
• The output current is fully limited if the battery voltage is below the Threshold voltage and above the Critical error voltage (min). This state is indicated by the "Undervoltage" status. The controller automatically recovers if the voltage rises above the Threshold voltage.
• The controller falls into critical error if the battery voltage falls below the Critical error voltage (min). The controller does not recover automatically, it needs to be turned OFF and ON again.

Motor nominal voltage

The AM controller is a DC to AC converter and can drive many types of electric motors.

For DC motors (brushed DC, BLDC / trapezoidal) -- nominal voltage of the motor should be equal to battery nominal voltage, because the nominal voltage of the motor is defined as DC voltage.

For AC motors (induction, BLAC / sinusoidal) -- nominal voltage of the motor should be 1.414 times lower than battery nominal voltage, because the nominal voltage of the motor is defined as link voltage (RMS value of sinusoidal voltage between two phases).

Output current and power rating

Infinite heatsink, BLDC

Controller mounted inside aluminium enclosure, thermally connected to infinite heatsink not exceeding 60 �C, with BLDC motor connected.

Parameter	0420	0610	0810	1010
Maximum power dissipation	20 W	20 W	20 W	20 W
Nominal power (60 min)	1700 W	2200 W	2400 W	2700 W
Nominal current (60 min)	60 A	51 A	42 A	38 A
Battery current	60 A	51 A	42 A	38 A
Peak power (10 sec)	3400 W	4300 W	4600 W	5000 W
Peak current (10 sec)	120 A	100 A	80 A	70 A

Infinite heatsink, BLAC / Induction

Controller mounted inside aluminium enclosure, thermally connected to infinite heatsink not exceeding 60 �C, with BLAC or induction motor connected.

Parameter	0420	0610	0810	1010
Maximum power dissipation	20 W	20 W	20 W	20 W
Nominal power (60 min)	1700 W	2100 W	2200 W	2500 W
Nominal current (60 min)	50 A	40 A	32 A	28 A
Battery current	61 A	49 A	39 A	34 A
Peak power (10 sec)	3500 W	3700 W	4200 W	4400 W
Peak current (10 sec)	100 A	70 A	60 A	50 A

Al housing still air, BLDC

Controller mounted inside aluminium enclosure, placed in still air at 25 �C, with BLDC motor connected.

Parameter	0420	0610	0810	1010
Maximum power dissipation	20 W	20 W	20 W	20 W
Nominal power (60 min)	1200 W	1500 W	1600 W	1800 W
Nominal current (60 min)	41 A	35 A	28 A	25 A
Battery current	41 A	35 A	28 A	25 A
Peak power (10 sec)	3400 W	4300 W	4600 W	5000 W
Peak current (10 sec)	120 A	100 A	80 A	70 A

Al housing still air, BLAC / Induction

Controller mounted inside aluminium enclosure, placed in still air at 25 �C, with BLAC or induction motor connected.

Parameter	0420	0610	0810	1010
Maximum power dissipation	20 W	20 W	20 W	20 W
Nominal power (60 min)	1100 W	1300 W	1400 W	1600 W
Nominal current (60 min)	32 A	25 A	20 A	18 A
Battery current	39 A	30 A	25 A	22 A
Peak power (10 sec)	3500 W	3700 W	4200 W	4400 W
Peak current (10 sec)	100 A	70 A	60 A	50 A

Shrinking tube, BLDC

Controller mounted in shrinking tube, placed in still air at 25 �C, with BLDC motor connected.

Parameter	0420	0610	0810	1010
Maximum power dissipation	5 W	5 W	5 W	5 W
Nominal power (60 min)	1200 W	1500 W	1600 W	1800 W
Nominal current (60 min)	27 A	22 A	18 A	16 A
Battery current	27 A	22 A	18 A	16 A
Peak power (10 sec)	2700 W	3200 W	3700 W	4300 W
Peak current (10 sec)	95 A	75 A	65 A	60 A

Shrinking tube, BLAC / Induction

Controller mounted in shrinking tube, placed in still air at 25 �C, with BLAC or induction motor connected.

Parameter	0420	0610	0810	1010
Maximum power dissipation	5 W	5 W	5 W	5 W
Nominal power (60 min)	700 W	850 W	850 W	970 W
Nominal current (60 min)	20 A	16 A	12 A	11 A
Battery current	25 A	20 A	15 A	14 A
Peak power (10 sec)	2600 W	3400 W	3500 W	4000 W
Peak current (10 sec)	75 A	65 A	50 A	45 A

note

Listed power (peak and nominal) is output power from the controller (input power to the motor). Output power from the motor (mechanical power) depends on the efficiency of the motor and controller settings.

Output protection and current limiting

Inputs and outputs are protected against shorting in the following manner:

• Each phase is protected against shorting to another phase
• Phase A and C are protected against shorting to BATT+ and BATT-
• Signal pins with voltage lower than 5 V are protected against shorting to each other

Advanced protections such as maximal power protection, undervoltage, overvoltage, thermal protection, and cycle-by-cycle current limiting are also implemented.

Additional electrical parameters

Parameter	Value	Notes
PWM frequency	20 kHz
Minimum pulse width	1 us
Maximum electrical revolutions	100,000 el. RPM
Minimum motor inductance	15 uH	Phase to phase
Battery / power supply impedance	---	Comparable or less than motor impedance

warning

The higher the battery impedance, the higher the voltage spikes caused by flowing current. If the voltage spikes exceed the non-operational overvoltage limit, controller damage could occur.

Thermal specification

Parameter	Value	Conditions
Maximum power dissipation	20 W	Controller thermally connected to infinite heatsink at max 60 �C
	10 W	Controller in aluminium housing, still air at 25 �C
	5 W	Controller in shrinking tube or bare PCB, still air at 25 �C
Thermal resistance	2.5 K/W	To the bottom pad of aluminium housing
Limiting temperature	90 �C	Measured inside the controller near transistors; above this, output power is limited

Power dissipation calculation

During controller operation, heat is generated inside the controller. Two major mechanisms are at play: conductance losses and switching losses. Conductance losses are proportional to resistance and square of current. Switching losses are proportional to frequency, battery voltage, motor current, and switching time of transistors.

Power dissipation is calculated from this formula:

P_TOT = 1 + kc * I_N^2 + ks * V_BATT * I_N [W]

Where V_BATT is battery voltage in volts, I_N is nominal motor current in amps (DC value for DC motors, RMS value for AC motors).

Power loss coefficients

Assembly code	kc (DC motor)	ks (DC motor)	kc (AC motor)	ks (AC motor)
0420	0.0047	0.00084	0.0070	0.0023
0610	0.0063	0.00087	0.0094	0.0024
0810	0.0092	0.00095	0.0139	0.0026
1010	0.0112	0.00097	0.0166	0.0026

Mounting and cooling tips

• Place controller in a well ventilated area. Use a sealed, waterproof housing and put it outside the vehicle rather than inside. Contact with moving air improves cooling.
• If possible, fasten the controller to large metal parts, such as a frame. This works as a heatsink and helps conduct heat away.
• If using an external heatsink or fastening the controller to metal parts, make sure both surfaces are flat, clean, and fit to each other. Apply a suitable amount of thermal grease to both surfaces.
• Use a thin layer of thermal grease rather than too much.

Environmental specification

Parameter	Min	Typ	Max	Unit
Operation temperature (no power limitation)	-20		60	�C
Operation temperature (limited power)	-20		80	�C
Humidity	5		85	%
Ingress protection -- sealed electronics		IP65
Ingress protection -- non-sealed electronics		IP40
Ingress protection -- JST JWPF connectors (mated)		IPX7
Ingress protection -- HIGO connectors (mated)		IP66

note

• Long device operation at high temperatures reduces the device lifespan.
• Sealed rating requires sealed enclosure and cables secured against any movement.
• Non-sealed rating applies when enclosure is non-sealed or cables are not secured.
• All connectors must be properly mated for the stated ingress protection.

EMC specifications and guidelines

The controller performs rapid switching of high currents, which can generate electromagnetic interference. EMC performance depends on the whole product, not only on the controller. To improve EMC performance:

• Use power wires with appropriate cross-section. Higher cross-section means lower resistance, lower voltage drops, and lower thermal losses.
• Use short wires when possible.
• Use shielded cables. Connect shielding to appropriate ground on one side only to prevent ground loops.
• Use twisted pairs. Differential signal wires (e.g. CAN Low and CAN High) should be twisted together.
• Twist power wires. Twist BATT+ with BATT- and twist motor phases A, B, and C together.
• Place signal wires separately from power wires. When crossing, signal wires should be perpendicular to power wires.
• If possible, connect motor chassis to BATT- close to the controller. If not possible, use a Y capacitor between them.
• Use galvanic isolation to prevent ground loops.
• Use signals with appropriate grounds. Do not mix signal grounds and power grounds.