The 7th generation ACS motor controllers

AC Superdrive (ACS) is a family of inverters/motor controllers with power levels from 10 to 80k VA , designed for nominal voltages between 24 V and 96 V. The ACS is developed with traction, hydraulic pump and generator applications in mind which makes it an ideal choice for most battery-powered electric vehicles.

The 7th generation ACS features very high power density. The logic platform, which is common to the entire power electronics range of Inmotion, offers unparalleled flexibility in software customization, as well as adherence to demanding functional safety requirements.

All ACS feature CAN bus communication and have extended I/O option for standalone operation, or to facilitate distribution of vehicle control and I/O functionality in an overall system.

Some models are available as dual (AC + AC) controllers.

Some models in the GEN7 family are still in development, please contact us for information on availability of prototypes for evaluation.

  • Outstanding quality and reliability, achieved through superior design and world class manufacturing processes.
  • Rugged design suitable for the demanding environment of electric vehicles. Protected against ingress of dust and water according to IP65.
  • Powerful MCU with an efficient operating system capable of parallel execution of motor control as well as customized vehicle control tasks.
  • Firmware with built-in standard functionality for common traction, generator and pump applications.
  • Software quality assured through development and review processes designed for Automotive SPICE® and ISO13849-1 compliance.
  • I/O version available for standalone operation or for distributed system I/O.
  • Industry standard CANopen and J1939 for reliable communication in a vehicle system.
  • Control of AC induction, AC synchronous, BLDC, and synchronous reluctance machines.
  • Selected models available as dual (AC + AC) controllers.
  • Dual MCU's and dual feedback channels for redundant cross monitoring and supervision, allowing ISO13849-1, category 3 implementation of safety functions up to PL=d.
  • State of the art vector control for optimal efficiency throughout the full speed range.
  • Auto-tuning of motor parameters for rapid commissioning of inverters into an existing vehicle.
  • Extensive and powerful event handling and data logging to simplify troubleshooting and minimize vehicle down time.

General

Motor type Induction AC, Synchronous AC, Brushless DC
Communication CAN (CANopen, J1939)
Switching frequency 4, 8, 12, 16 kHz
Operating stator frequency 0-599 Hz
Control mode Speed (rpm), Torque (Nm), Current (ARMS) or Voltage (VDC)
Connector AMP SEAL 23-pin or AMP SEAL 35-pin
Operating temperature -40 °C to + 55 °C (- 40 °F to + 131 °F)
Storage temperature -40 °C to + 85 °C (- 40 °F to + 185 °F)
Protection class IP65
Standards UL 583 and EC declaration of incorporation of partly completed machinery according to directive 2006/42/EC and 2014/30/EU i.e. C-standard EN 1175-1 and EN 12895

 Ratings

ACS model Nominal DC
supply voltage
Udc
Rated current
(S2, 2 min)
ARMS^^
Rated current
(S2, 1 h)
ARMS^^^
Rated power
(S2, 2 min)
kVA^^
Rated power
(S2, 1 h)
kVA^^^

ACS S

ACS24S35^ 24 350 150 10 4
ACS48S28^ 48 280 120 17 7

ACS M (also available as dual inverter, MD^)

ACS24M55 24 550 275 16 8
ACS48M35 48 350 175 21 10
ACS48M45 450 225 27 13
ACS48M55 550 275 32 16
ACS80M23 80 230 115 23 11
ACS80M35 350 175 34 17
ACS80M40 400 200 39 20
ACS96M23 96 230 115 27 14
ACS96M35 350 175 41 21
ACS96M40 400 180 47 21

ACS L

ACS48L70 48 700 350 41 21
ACS48L90 900 450 53 27
ACS80L50 80 500 250 49 25
ACS80L60 600 300 59 29
ACS80L70 700 350 69 34
ACS96L50 96 500 250 59 29
ACS96L60 600 300 71 35
ACS96L70 700^^^^ 350 82 41

^ Available with 35-pins I/O connector

^^ 2 minute rating at 8 kHz switching frequency and 25 ºC ambient temperature

^^^ 1 hour rating at 8 kHz switching frequency. 40 ºC ambient temperature. and 6 m/s air flow through finned heat sink
^^^^ Current rating limited to S2 90 seconds

Overview

ACS GEN7 is available in different sizes, depending on available power and number of axles controlled, as described in table below.

Model S M M--D L
Multi axle - - Dual -
Link to picture
Footprint 150 x 200 mm 200 x 150 mm 200 x 275 mm 200 x 235 mm
Max power (peak/cont) 16.5/7.1 kVA 39.2/19.6 kVA 68.6/34.3 kVA
Heat sink options C, Y, T C, Y, T C, Y, Q C, W, Y
Power terminal options Threads (M6) Threads, studs (M8) Threads, studs (M8) Threads, studs (M8)
I/O options 35 pins 23 pins , 35 pins 35 pins-Dual 23 pins, 35 pins

Heat sink options

In order to facilitate cost efficient mounting options for a variety of vehicle designs, there are several different heat sink options for both forced air cooling and conduction cooling (finned and flat heat sinks respectively). The table below outlines the heat sink options.

Heat sink version C Y T Q W
Type Flat Fin Fin Fin Liquid
Width 200 mm 200 mm 150 mm 275 mm 285 mm
Profile C_HS Y_HS T_HS T_HS  Heat sink W Visio

Power terminal options

Power terminals are normally a threaded hole to facilitate mounting of power cables with screws and washers. Optionally most models can be fitted with studs to allow mounting power cables with nuts and washers.

I/O options

ACS GEN7 comes with an option of I/O to optimally suit most applications. The 23 pin interface (23P) is optimized for slave units in a CAN network, with limited I/O capacity. The 35 pin interface (35P) features a larger number of I/O to be used by the application software for standalone operation, vehicle control, or as distributed I/O in a vehicle network. The dual inverter I/O (35P-D) requires more motor interface pins and is thus slightly different. Below is an outline of the various I/O options of ACS GEN7.

I/O version 23 Pins 35 Pins 35 Pins-Dual
Dedicated HW ID 2 - -
Multifunction I/O* 3 5 5
Digital inputs - 9 5
Analog inputs - 2 -
High side in/out 1 1 1
Sensor supply 1 2 2
Current control output 2 2 4
PWM control output - 2 -
On/off output - 2 -
CAN** 2 1 2
Motor temp 1 1 2

* Multifunction I/O can be used as motor feedback, analog in, or digital in. Motor feedback supported is encoder, UVW (6-step), analog sin/cos.

** CAN interface consists of CAN_HIGH, CAN_LOW and CAN_GND. The 23P and 35P-D versions have two of each pin to facilitate daisy-chaining in a network. Additionally all inverters have a CAN_120 pin that serves to terminate the CAN bus if a jumper is placed in the wiring harness.