Sevcon Controller Guide: Millipak, MicroMos, MOS90, Powerpak, Gen4 and Gen5

A 633T45320 and a 634A44133 are both Sevcon controllers rated around 48 V and they have almost nothing else in common — different family, different motor type, different programming tool. This page sorts the range by family so you can place the part number in your hand. Everything listed is stocked new.

The families, and what each is for

  • Millipak (633…) — compact DC traction and pump controllers. The workhorse on industrial sweepers, scrubbers and small material-handling equipment. SEM variants are the separately excited versions.
  • MicroMos and MOS90 (631…) — DC traction and pump controllers, MOS90 being the larger frame and the higher current.
  • Powerpak (632…) — DC traction controllers, including the Hyundai forklift OEM variants.
  • Gen4 (634…) — the AC and PMAC family, sized by frame: Size 2, 4, 6, 8. This is what goes into a modern AC conversion. Frame size sets both the current capability and the physical footprint.
  • Gen5 (636…) — the high-voltage successor; the unit we carry is 450 V, Size 9.
  • HVLP — high-voltage, low-power, air-cooled.

On Gen4, feedback type matters more than the current rating

Gen4 controllers are built for a specific motor feedback device, and this is not a software setting:

  • Sin/Cos units expect an analogue sine/cosine encoder.
  • AB units expect a digital quadrature encoder.

A Sin/Cos controller will not commutate a motor fitted with an AB encoder however well the voltage and current match, and the reverse is equally true. Check what your motor has before you choose. If you are specifying a new build, decide the feedback type first and let it drive the controller choice, not the other way round. The same applies to the Size 8 resolver variants, where the resolver ratio in the listing — 0.29 or 0.5 — has to match the motor.

DC families: Millipak, MicroMos, MOS90 and Powerpak

Family Part number Voltage Current
Millipak 633C43104 48V 300A
Millipak 633T43810 48V 4Q, ask
Millipak 633T43812 48V ask
Millipak 633T43819 24/48V 300A
Millipak 633T45303 48V 500A
Millipak 633T46101 48V 600A
Millipak 633T46301 48V traction, ask
Millipak 633T46502 48V pump, ask
SEM Millipak 633T45320 24/48V 500A
MicroMos 631F50101 24/48V ask
MicroMos 631F55314 24/48V 250A
MOS90 63140243 24/80V 270A pump
MOS90 63146005 80V 420A traction
Powerpak 632P44305 24/48V Hyundai OEM
Powerpak 632P44536 24/48V ask
Powerpak 632S45617 24–48V 400A
Powerpak 632S45658 24/48V Hyundai SEM
Powerpak 632S84627 80V 425A

Browse the full listings: Millipak, Powerpak, or everything Sevcon.

AC families: Gen4, HVLP and Gen5

Family Part number Voltage Current Frame Feedback
Gen4 634A23203 24V 300A Size 2 Sin/Cos
Gen4 634A23206 24V 300A Size 2 Sin/Cos
Gen4 634A34203 24/36V 450A Size 4 Sin/Cos
Gen4 634A36203 24/36V 650A Size 6 Sin/Cos
Gen4 634A42203 36/48V 275A Size 2 Sin/Cos
Gen4 634A42206 36/48V 275A Size 2 Sin/Cos
Gen4 634A44103 36/48V 450A Size 4 AB
Gen4 634A44130 48V 450A Size 4 ask
Gen4 634A44133 48V 450A Size 4 ask
Gen4 634A44206 36/48V 450A Size 4 Sin/Cos
Gen4 634A46203 36/48V 650A Size 6 Sin/Cos
Gen4 634A81206 72/80V 180A Size 2 Sin/Cos
Gen4 634A83207 72/80V 350A Size 4 Sin/Cos
Gen4 634A85101 72/80V 550A Size 6 AB
Gen4 634A85203 72/80V 550A Size 6 Sin/Cos
Gen4 634A85210 72/80V 550/750A Size 6 Sin/Cos
Gen4 634A13202 96/120V 300A Size 4 Sin/Cos
Gen4 634H83203 400V 300A Size 8 0.29 resolver
Gen4 634H83204 400V 300A Size 8 0.5 resolver
HVLP 634L10202 high voltage 10 kW air cooled ask
Gen5 636A34901 450V 400A Size 9 ask

Full listings: Sevcon Gen4 and everything Sevcon.

Programming: three families, three different tools

There is no single Sevcon programmer, and this catches people out. Match the tool to the family:

A Gen4 controller out of the box is rarely ready for a specific vehicle. If you are converting something, budget for the DVT tool or have us configure the unit before it ships.

DC-DC converters on the same platform

We stock the Sevcon 300 W and 500 W converter range from 24 V through 96 V input, plus a 220–800 VDC 1.2 kW unit for traction packs. If you are running 12 V lighting or accessories off a 48 V or 72 V pack, that is the right part rather than tapping one battery in the string — here is why tapping fails. Browse the DC-DC converter range.

Need help matching one?

Send the part number off the controller, the motor’s make and feedback type, and the pack voltage. Email matt@electricdrivesolutions.com or call (717) 421-9988.

Everything we sell is new — no remanufactured units, no core charges. See our Brand New Promise and warranty policy.

Ratings are the manufacturer’s. Where a cell reads “ask”, the figure is not stated on the unit’s own datasheet listing and we will confirm it for your part number. Verify against the current datasheet before ordering.

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