Motor controllers for DIY electric boats: Kelly KLS-N vs Sevcon Gen4

A packaged drive from Oceanvolt, Torqeedo or ePropulsion includes its controller. If you're building your own drive around a separate motor, the controller is the part you have to size yourself — and its continuous current rating, not the headline peak, is what matters for a boat.

Both makers publish current ratings for limited periods. The checker compares them with the continuous phase current the configurator calculates for your power and voltage.

Manufacturer figures, checked 22 October 2026Sources & disclosure
What fits your boat?
Continuous phase current: 347 A

Don't know your figures? Size your boat in the configurator — it works out power, voltage, pack size and phase current from your hull and target speed.

Side by side

 
Kelly Controls
KLS-N, 36–48 V models
Kelly Controls
KLS-N, 48–72 V models
Sevcon (BorgWarner)
Gen4 Size 4 / Size 6, 36–48 V
Sevcon (BorgWarner)
Gen4 Size 4, 96–120 V
Nominal voltage (operating range)36–48 V (27–60 V)48–72 V (36–86 V)36–48 V (19.3–69.6 V)96–120 V (48–150 V)
Peak current140–700 A (1–2 min)140–700 A (1–2 min)450 / 650 A phase (2 min)300 A phase (2 min)
Continuous current60–420 A, depending on model and heat sinking50–420 A, depending on model and heat sinking180 / 260 A phase (60 min)120 A phase (60 min)
Motor typesBrushless PM with hall sensors (sinusoidal)Brushless PM with hall sensors (sinusoidal)PMSM (incl. BLDC) and AC inductionPMSM (incl. BLDC) and AC induction
ProtectionIP66IP66IP66IP66
CommunicationBroadcast CAN, 250 kbpsBroadcast CAN, 250 kbpsCANopenCANopen

Scroll sideways on a phone. “Not stated” means the manufacturer's page doesn't give the figure.

Which one for which boat

Budget 48 V DIY
Kelly Controls KLS-N, 36–48 V models

Wide range of models, IP66, regen by default.

Clear continuous ratings at 48 V
Sevcon (BorgWarner) Gen4 Size 4 / Size 6, 36–48 V

60-minute phase ratings, induction and PM motors, CANopen.

96 V DIY
Sevcon (BorgWarner) Gen4 Size 4, 96–120 V

The only controller here rated for a 96 V bus.

The products

Kelly Controls

KLS-N, 36–48 V models

Sinusoidal BLDC/PMSM · 36–48 V · IP66
Good for

Budget DIY builds at 48 V, from small launches up to the larger NC models.

Check before buying

The higher continuous figures depend on extra heat sinking — design the cooling, don't assume the top of the range.

Kelly Controls

KLS-N, 48–72 V models

Sinusoidal BLDC/PMSM · 48–72 V · IP66
Good for

48 V builds that want headroom above the battery's charge voltage.

Check before buying

Not rated for a 96 V bus (86 V maximum operating voltage).

Sevcon (BorgWarner)

Gen4 Size 4 / Size 6, 36–48 V

AC induction & PMSM · 36–48 V · IP66
Good for

48 V builds that want an automotive-grade, highly configurable controller with clear 60-minute ratings.

Check before buying

Configuration needs Sevcon's tools and some experience; budget for setup time.

Reading the numbers

Questions

Common questions

What size motor controller do I need for an electric boat?+
Size it on continuous phase current at your lowest battery voltage, not on the peak rating. The configurator calculates the continuous phase current for your motor power and voltage; choose a controller whose continuous rating covers it with margin.
Kelly or Sevcon?+
Kelly is the budget option with many models and IP66 housings; its higher continuous ratings depend on heat sinking. Sevcon's Gen4 publishes 60-minute phase-current ratings, drives both PM and induction motors, and talks CANopen, at a higher price and with more involved setup.
Background reading
Sources & disclosure

Figures checked on 22 October 2026 against these manufacturer documents. Makers change specifications; confirm against the current datasheet before you buy.

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