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AC Motor Controller
Gen4 Size 2/4/6

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AC Motor Controller Gen4 (Size 2/4/6)
Integrated I/O
The Gen4 range represents a well established design in com- Gen4 includes a fully-integrated set of inputs
pact AC controllers. These reliable controllers are intended for and outputs (I/0) designed to handle a wide
range of vehicle requirements. This eliminate
on-road and off-road electric vehicles and feature the smallest the need for additional external I/O modules
size in the industry for their power capacity. or vehicle controllers and connectors.
8 digital inputs
Thanks to the high efficiency it is possible to integrate these 2 analogue inputs (can be configured
controllers into very tight spaces without sacrificing perfor- as digital)
3 contactor/solenoid outputs
mance. The design has been optimised for the lowest possible
1 encoder supply output – programmable
installed cost while maintaining superior reliability in the most
5 V or 10 V
demanding applications. Motor temperature sensor input
Motor encoders supported include
UVW hall effect sensors, Sin/Cos sensors
and incremental AB encoders

Features
Advanced Field Oriented Control CANopen protocols
AC Permanent Magnet Synchronous motor Configurable as a vehicle control master
control, including salient, non-salient and or as a motor control slave
BLDC motors Autocheck system diagnostic
AC induction motor control Hardware & software failsafe watchdog
CAN communications bus allows for operation
easy interconnection of controllers and Integrated fuse holder
devices such as Battery Management IP66 protection
Systems, displays and VCUs Highly configurable

Key Parameters
Model Size 2 Size 4 Size 6 Size 2 Size 4 Size 6 Size 2 Size 4 Size 6 Size 4
Nominal 24 24 – 36 36 – 48 72 – 80 96 – 120
Battery Voltage VDC VDC VDC VDC VDC
Maximum 34.8 52.2 69.6 116 150
Operating Voltage VDC VDC VDC VDC VDC
Minimum
12.7 VDC 19.3 VDC 39.1 VDC 48 VDC
Operating Voltage
Peak Phase
300 A 450 A 650 A 275 A 450 A 650 A 180 A 350 A 550 A 300 A
Current (2 min)
Boost Phase
360 A 540 A 780 A 330 A 540 A 780 A 215 A 420 A 660 A 360 A
Current (10 sec)
Continuous Phase
120 A 180 A 260 A 110 A 180 A 260 A 75 A 140 A 220 A 120 A
Current (60 min)
© BorgWarner 2019/ACMCGEN4S2-4-6

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AC Motor Controller
Gen4 Size 8

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AC Motor Controller Gen4 (Size 8)
Integrated I/O
An AC motor controller designed to meet the high performance The Gen4 Size 8 includes a fully-integrated
requirements of on-road and off-road Electric (EV) and Hybrid set of inputs and outputs (I/O) designed
to handle a wide range of vehicle functions.
Electric Vehicles (HEV). This eliminates the need for additional exter-
nal I/O modules or vehicle controllers and
A compact, rugged and cost effective design, the Gen4 Size 8 connectors.
is well suited for EV OEMs, EV conversions and EV drive train All I/O protected to 40 V
system integrators. Its high voltage range, up to 400V DC, is well 4 analogue inputs 0 – 10 V
4 digital inputs
matched to the needs of the automotive and commercial trans-
3 power supplies 0 – 10 V 100 mA
port markets. The same hardware platform handles both AC 3 contactor/solenoid outputs max 2 A
Induction and Permanent Magnet AC motor technologies. Motor temperature sensor input
Programmable 5 V to 10 V encoder supply
Motor encoders supported include
Resolver, UVW hall effect sensors, Sin/Cos
sensors and incremental AB encoders
Features Key Parameters
Advanced Field Oriented Control Operating voltage range 128 V to 400 VDC
AC Permanent Magnet Synchronous motor Output motor phase current:
control, including salient, non-salient and • 400 Arms (boost)
BLDC motors • 360 Arms (30sec)
AC induction motor control • 300 Arms (2 min)
CAN communications bus allows for easy • 200 Arms (continuous)
interconnection of controllers and devices Water/Glycol cooling
such as Battery Management Systems, Forced air or oil cooled options also
displays and VCUs available (output rating subject to change)
CANopen and J1939 protocols
Safety:
Configurable as a vehicle control master
• Electrical safety to ISO 6494, IEC 60664
or as a motor control slave 322 mm (L) x 322 mm (W) x 107 mm (H)
Integrated logic circuit, 12 V or 24 V nominal and UL840
Up to 400 VDC supply voltage • Pulsed safety enable input
Up to 100 kW peak power output • Pulsed status output
Environmental:
Up to 60 kW continuous power output
Includes an additional dedicated safety • –40°C to +85°C operation
• IP66 protection
supervisory processor
Safety interlock pulsed enable signal • ISO 16750
IP66 protection
Highly configurable © BorgWarner 2019/ACMCGEN4S8

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AC Motor Controller
Gen4 Size 10

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AC Motor Controller Gen4 (Size 10)
Integrated I/O
An AC motor controller designed to meet the high Gen4 Size 10 includes a fully-integrated
set of inputs and outputs (I/0) designed to
performance requirements of on-road and off-road handle a wide range of vehicle requirements.
Electric (EV) and Hybrid Electric Vehicles (HEV). This eliminated the need for addi­tional
external I/O modules or vehicle controllers
The Gen4 Size 10 is capable of operation up to 800 VDC and connectors.
All I/O protected to 40 V
and up to 450 A rms phase current. 4 analogue inputs 0 – 10 V
4 digital inputs
3 power supplies 0 – 10 V 100 mA
3 contactor/solenoid outputs max 2 A
Motor temperature sensor input
Features Configurable as a vehicle control master
Programmable 5 V to 10 V encoder supply
or as a motor control slave
Advanced Field Oriented Control Motor encoders supported include
Integrated logic circuit, 12 V or 24 V nominal
AC Permanent Magnet Synchronous Resolver, UVW hall effect sensors, Sin/Cos
Up to 800 VDC supply voltage
motor control, including salient, non-salient sensors and incremental AB encoders
Up to 300 kW peak power output
and BLDC motors
Up to 150 kW continuous power output
AC induction motor control
Includes an additional dedicated safety
CAN communications bus allows for Key Parameters
supervisory processor
easy interconnection of controllers and Operating voltage range at full
Safety interlock pulsed enable signal
devices such as Battery Management current 50 V to 800 V
Systems, displays and VCUs Highly configurable
Output motor phase current:
CANopen and J1939 protocols
• 400 A rms (2 min)
• 200 A rms (Continuous)
Water/Glycol coolant (oil cooling
available for custom applications)
Weight: 10.9 kg

Dimensions

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AC Motor Controller
Gen5 Size 9

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AC Motor Controller Gen5 (Size 9)
Intelligent I/O
The Gen5 range of products is well-matched to satisfy The Gen5-S9 includes a fully-integrated
set of inputs and outputs designed to
automotive, commercial and construction markets’ elec­ handle a wide range of vehicle functions.
trification needs. The Gen5 Size 9 is specifically aimed at This eliminates the need for additional
external I/O modules or vehicle controllers
vehicle OEMs and system integrators to offer them a com- and connectors.
All I/O protected to 40 V
pact, lightweight, robust and cost-effective, class-leading 4 analogue inputs 0 – 10 V allowing for
suite of solutions covering traction, hybridisation, power easy configuration of dual throttle and
dual brake applications
generation and sub-system electrification. 2 PT1000/KTY84 thermocouple input
4 digital inputs
4 digital outputs PWM 2A
(2 high side 2 low side)
3 programmable encoder power supplies
Key Parameters Features (1x200 mA 2x100 mA voltage configurable)
Motor encoders supported include Resolver
Operating voltage up to 450 Vdc Advanced Field Orientated Control
(programmable gain), UVW hall effect
(de-rating above 420 V) with support for Permanent Magnet
sensors, Sin/Cos sensors and incremental
Output motor phase current Synchronous Motors and AC Induction
AB encoders
• 450 Arms (1 min) Motors
• 200 Arms (1 hour+) I/O and CAN are electrically isolated
Safety CAN communications bus allows for easy
Dimensions
• HVIL safety functionality interconnection of controllers and devices
Environmental such as Battery Management Systems,
• –40°C to +85°C operation, IP6k9k, displays and VCUs
ISO 16750 CANopen and J1939 protocols
• Water/Glycol coolant flow rate Configurable as a vehicle control master
10 l/minute (de-rating above 55°C) or as a CAN motor torque slave
12 V or 24 V logic supply
Note: key parameters can vary,
depending on controller set-up,
environmental conditions and
motor conditions.

Weight 6.8 kg
© BorgWarner 2021/GEN5-S9

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AC Motor Controller Dragon 8

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AC Motor Controller (Dragon 8)
The Dragon8 sets a new standard in AC motor controller
performance and reliability. It is compatible with a wide range
of motors – Asynchronous AC Induction and Synchronous
Permanent Magnet AC (PMAC) or Brushless DC (BLDC).

Dragon8 has electrical isolation between high power battery/

motor wiring and the lower voltage control signals and CANBus.
This allows the IO to reference the 12 V (or 24 V) battery and
vehicle chassis return path.

Features Integrated I/O Key Parameters

Integrated & isolated IO and logic circuit Dragon8 includes a fully integrated set
96 V Version
Supports AC Induction and PMAC/BLDC of inputs and outputs (I/O) with vehicle
Isolated CAN communications bus allows control functionality, designed to handle
Nominal Battery
a wide range of system requirements and 48 V – 96 V
for easy interconnection of controllers Voltage
and devices such as Battery Management functions. This frequently eliminates the
Maximum
Systems, displays and VCUs need for additional external I/O modules, 139 V
Operating Voltage
CANopen and J1939 protocols vehicle control units and connectors.
Up to 6 digital inputs (3 inputs dual use Minimum
Configurable as a vehicle control master 20 V
Operating Voltage
or as a motor control slave as UVW encoder input)
Up to 4 analogue input (2 analogue inputs Boost Phase
Power up auto-check system fault 400 A rms
Current (10 seconds)
diagnostics dual use as Sin/Cos encoder input)
Up to 2 contactor drivers Peak Phase
Programmable battery current limit 300 A rms
Dedicated 5 V, 200 mA output Current (2 minutes)
IP66 protection
Dedicated 10 V, 200 mA output Continuous Phase
Integrated power fuse holder 110 A rms
Motor temperature sensor input Current (1 hour)
Motor encoders supported include
Resolver (programmable gain), UVW
hall effect sensors, Sin/Cos sensors
and incremental AB encoders

227 mm (L) x 138 mm (W) x 73 mm (H), Weight 2 kg

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High Voltage Low Power Inverter

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High Voltage Low Power Inverter
A new range of low power AC motor controllers/inverters
designed primarily for ancillary control of pumps and fans
on hybrid and electric buses, agricultural implements,
tractors and other high voltage vehicles. There are two
models in the range, which cover both liquid cooled and
air cooled designs.

Features All I/O protected to 40V

4 analogue inputs 0 – 10V
Advanced Field Oriented Control
4 digital inputs
AC Permanent Magnet Synchronous
2 power supplies 5 – 10V Air Cooled HVLP-10
motor control, including salient,
(100 mA & 200mA)
non-salient and BLDC motors
2 digital outputs
AC induction motor control without
Motor temperature sensor input
speed sensor
Motor encoders supported include
Operation without a position sensor
Resolver (programmable gain), UVW
for PMSM motors supported for custom
hall effect sensors, Sin/Cos sensors
applications
and incremental AB encoders
200 V to 800 VDC battery voltage
Up to 53 A peak current (HVLP-20)
Up to 33 A continuous current (HVLP-20)
CAN communications bus allows for easy
Key Parameters
interconnection of controllers and devices HVLP-10 (air cooled)
such as Battery Management Systems, Operating voltage range at full current
displays and VCUs 200 V to 800V

All dimensions in mm.

CANopen and J1939 protocols Output motor phase current:
Configurable as a vehicle control master • 24 A rms (1 min)
(including pump and generator control) • 19 A rms (Continuous)
or as a motor control slave Ambient –40°C up to +45°C full operation
High Voltage Interlock (HVIL) Weight: 3.7 kg
12 V or 24 V nominal supply
HVLP-20 (liquid cooled)
Highly configurable Liquid Cooled HVLP-20
Operating voltage range at full current
200 V to 800V
Output motor phase current: Common Parameters
Integrated I/O • 53 A rms (1 min) Safety:
HVLP includes a fully-integrated set of • 33 A rms (Continuous) • HVIL (High Voltage Interlock H/W & S/W)
inputs and outputs (I/0) designed to handle Water/Glycol coolant • Designed to meet the electrical isolation
a wide range of requirements. This reduces • Full operation up to 70°C inlet of electrically propelled vehicles ISO 6469
the need for additional external I/O modules tempe­ra­ture and at 6/l min flow Environmental:
or vehicle controllers and connectors. Weight: 2.3 kg (dry) • IP6k9k and IP67 protection

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