AC Motor Controller Gen4 Size 10

borgwarner ac motor controller

BorgWarner - AC Motor Controller Gen4 (Size 10).

An AC motor controller designed to meet the high performance requirements of on-road and off-road Electric (EV) and Hybrid Electric Vehicles (HEV).
The Gen4 Size 10 is capable of operation up to 800VDC and up to 450 A rms phase current.


Integrated I/O

Gen4 Size 10 includes a fully-integrated set of inputs and outputs (I/0) designed to handle a wide range of vehicle requirements.
This eliminated the need for additional external I/O modules or vehicle controllers and connectors.

  • All I/O protected to 40V
  • 4 analogue inputs 0 – 10V
  • 4 digital inputs
  • 3 power supplies 0 – 10 V 100mA
  • 3 contactor/solenoid outputs max 2A
  • 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


  • Advanced Field Oriented Control
  • AC Permanent Magnet Synchronous motor control, including salient, non-salient and BLDC motors
  • AC induction motor control
  • CAN communications bus allows for easy interconnection of controllers and devices such as Battery Management Systems, displays and VCUs
  • CANopen and J1939 protocols
  • Configurable as a vehicle control master or as a motor control slave
  • Integrated logic circuit, 12 V or 24V nominal
  • Up to 800 VDC supply voltage
  • Up to 300 kW peak power output
  • Up to 150 kW continuous power output
  • Includes an additional dedicated safety supervisory processor
  • Safety interlock pulsed enable signal
  • Highly configurable

Key Parameters

  • Operating voltage range at full current 50 V to 800V
  • Output motor phase current:
    • 400A rms (2 min)
    • 200 A rms (Continuous)
  • Water/Glycol coolant (oil cooling available for custom applications)
  • Weight: 10.9 kg