Kelly Motor Controller
Contents
1. 17 571 Cleaning EEE aS 17 5 2 Configurations ree ahaa oa beater 17 Table 1 LED CODES AT A S A E NET TET 18 Contact Us Eaa EOE NEEESE ET EREE EEEE wie ts Sie ESETA EENET EE ENE ais slats EENE E ETSE 19 Page 1 Kelly KBS Brushless Motor Controller User s Manual V 4 1 Chapter 1 Introduction 1 1 Overview This manual introduces the Kelly Small BLDC motor controllers features their installation and their maintenance Read the manual carefully and thoroughly before using the controller Should you have any questions please contact the support center of Kelly Controls LLC Kelly s programmable motor controllers provide efficient smooth and quiet controls for electric motorcycles golf carts and go carts as well as industrial motor speed or torque control It uses high power MOSFET s and PWM to achieve efficiencies of up to 99 in most cases powerful microprocessor brings in comprehensive and precise control to the controllers It also allows users to adjust parameters conduct tests and obtain diagnostic information quickly and easily Page 2 Kelly KBS Brushless Motor Controller User s Manual V 4 1 Chapter 2 Features and Specifications 2 1 General functions 1 Extended fault detection and protection The LED flashing pattern indicates the fault sources 2 Monitoring battery voltage It will stop driving if the battery voltage is too high and it will p2. O Oo O O QO Q Figure 6 RS232 Interface 3 3 Installation Check List Before operating the vehicle complete the following checkout procedure Use LED code as a reference as listed in Table 1 Caution Put the vehicle up on blocks to get the drive wheels off the ground before beginning these tests Do not allow anyone to stand directly in front of or behind the vehicle during the checkout Make sure the PWR switch and the brake is off e Use well insulated tools Page 10 Kelly KBS Brushless Motor Controller User s Manual V 4 1 e sure the wiring is connected correctly Turn the PWR switch The Green LED stay on steadily and Red LED turns off when the controller operates normally If this does not happen check continuity of the PWR and return e The fault code will be detected automatically at restart e With the brake switch open select a direction and operate the throttle The motor should spin in the selected direction Verify wiring or voltage and the fuse if it does not The motor should run faster with increasing throttle If not refer to the Table 1 LED code and correct the fault as determined by the fault code Take the vehicle off the blocks and drive it a clear area It should have smooth acceleration and good power Page 11 Kelly KBS Brushless Motor Controller User s Manual V 4 1 Chapter 4 Programmable Parameter
3. 3 2 2 Wiring of KBS Controller ay ABU lt 0 N LH 1 0 TESSIDIU JOU 1 31 UO JAIN uM TIMO Q AS 0 INdjno pasn aq HALON IIAP 10 204 LIA MS ws 1019 0 D sjeu 22 10 30d MS 110 os i eg 7 IS ABAIY K JOJDOUUOD ALN YIM ISIA mlz Pe ison gt Yul C amasa MS Adu CAT PY z maa datn 1 asn4 youms Aay 4 ania AMY Wd 10290000 9 27010 2010 OMT UATIOULNOD Say Figure 3 KBS controller standard wiring Battery voltage can be used for controller supply Page 9 Kelly KBS Brushless Motor Controller User s Manual V 4 1 3 2 2 2 Optional wiring of KBS controller The output signal of the pin is for Kelly current meter From Controller Kelly Ampmeter Figure 4 wiring of current meter pin The 12V input signal of the pin supplies the second braking function of the controller BRK2 Reddle so 12 Vechile supply From Controller Break Switch RTN Black 12V Vechile supply Figure 5 wiring of BRK2 3 2 3 Communication Port A RS232 port is provided to communicate with host computer for calibration and configuration
4. 8V to 30V for 24V controller e Supply Current PWR 150 Configurable battery voltage range B Max operating range 18V to 1 25 Nominal Voltage Standard Throttle Input 0 5 Volts 3 wire resistive pot 1 4 Volts hall active throttle Analog Brake and Throttle Input 0 5 Volts Can use 3 wire pot to produce 0 5V signal Page 4 Kelly KBS Brushless Motor Controller User s Manual V 4 1 Reverse Alarm Main Contactor Coil Driver Meter lt 200mA Full Power Operating Temperature Range 0 to 50 controller case temperature Operating Temperature Range 30 to 90 C 100 C shutdown controller case temperature Motor Current Limit 10 seconds boost 50A 120A depending on the model Motor Current Limit continuous 20A 50A depending on the model Battery Current Configurable 2 4 Name Regulation The name regulation of Kelly BLDC motor controllers KBS438101 The eighth letter represents regeneration 0 non regeneration with regeneration The sixth and seventh letters represent the max current divided by 10 The fourth and fifth letters represent nominal voltage The first three letters represent Kelly s low power brushless motor controller Page 5 Kelly KBS Brushless Motor Controller User s Manual V 4 1 Chapter 3 Wiring and installation 3 1 Mounting the Controller The controller can be mounted in any position which should be as clean and dry as possible and if necessary
5. Balanced mode brings fast response of the load and wide speed adjusting range Speed mode brings smooth operation and wide speed adjusting range Suggestion Set according to the practical situation factory default is Torque mode 4 Under Voltage Value range Please see Figure 4 2 Functional description Controller will not operate when battery voltage is lower than the value so as to protect battery Suggestion Set according to the practical situation 5 Over Voltage Value range Please see Figure 4 2 Functional description Controller will not operate when battery voltage is higher than the value so as to protect battery and controller Suggestion Set according to the practical situation Controller Rated voltage Under Voltage Range V Over Voltage Range V 24V 12 30 12 30 Page 13 Kelly KBS Brushless Motor Controller User s Manual V 4 1 48V 18 60 18 60 72V 18 90 18 90 120V 18 136 18 136 144V 18 180 18 180 Figure 4 2 6 Throttle Up Down Rate Value range 0 100 Functional description Pedal AD Sampling Frequency a lower value means a shorter sampling period and a faster respond rate Suggestion Set according to the practical situation factory default is 30 7 High Pedal Disable Value range Enable and Disable Functional description If enabled the controller will detect the current pedal status at power up If throttle got effective output the controlle
6. Set brake sensor effective ending point Suggestion Set according to the practical situation factory default is 90 4 5 Step 5 1 Motor Temperature Sensor Value range Enable and Disable Functional description If use motor temperature sensor and enable this function Controller Stop Output Temperature and Controller Resume Output Temperature can be configured so as to achieve real time protection on the motor Suggestion Set according to the practical situation 2 Controller Stop Output Temperature Value range 60 C 170 C Functional description Controller will stop output if motor temperature reaches the set value Suggestion Set according to the practical situation 3 Controller Resume Output Temperature Value range 60 C 170 C Functional description Controller will resume output if motor temperature reaches the set value Suggestion Set according to the practical situation Note Thermistor is optional Default to KTY83 122 Page 16 Kelly KBS Brushless Motor Controller User s Manual V 4 1 Chapter 5 Maintenance There are no user serviceable parts inside the controllers Do not attempt to open the controller as this will void your warranty However periodic exterior cleaning of the controller should be carried out The controller is a high powered device When working with any battery powered vehicle proper safety precautions should be taken that include but are not limited to proper training wearing ey
7. shielded with a cover to protect it from water and other contaminants To ensure full rated output power the controller should be fastened to a clean flat metal surface with four screws Applying silicon grease or some other thermally conductive material to the contact surface will enhance thermal performance Proper heat sinking and airflow are vital to achieve the full power capability of the controller The case outline and mounting hole dimensions are shown in Figure 1 Height 41 millimeters Figure 1 mounting hole dimensions dimensions in millimeters Page 6 Kelly KBS Brushless Motor Controller User s Manual V 4 1 3 2 Connections 3 2 1 Pin definition of KBS Controller 5 Orange _ 17 16 Yellow Greeen Blue Hall A Hall B Hall C ee Female connector Figure 2 waterproof connector Hall Connector Pin Definition 21 RTN Signal return Black 5 5V 5V supply output lt 40mA Orange 18 Hall A Hall phase A Yellow 17 Hall B Hall phase B Green 16 Hall C Hall phase C Blue Page 7 Kelly KBS Brushless Motor Controller User s Manual V 4 1 Male Connector Pin Definition 14 REV_SW Reverse switch input Deep Blue 6 RTN Signal return or power supply return Black 11 Green LED Normal running indication Dark Gray 12 Red LED Fault code White 9 Relay Main contactor driver lt 200mA Blue 7 PWR Controller power supply input Pink 10 Alarm To d
8. 16 Configurable economy switch Limits the maximum current to half if the switch is turned on 17 Maximum reverse power is configurable to half power 18 Enhanced regen brake function A novel ABS technique provides powerful and smooth regen 19 Configurable 12V brake signal input in lieu of motor temperature sensor 20 Optional joystick throttle A bi symmetrical 0 5V signal for both forward and reversing 21 Configurable motor over temperature detection and protection with the recommended thermistor KTY83 122 22 3 hall position sensor inputs Open collector pull up provided 23 Optional supply voltage 8V 30V Caution Regeneration has braking effect but does not replace the function of a mechanical brake A mechanical brake is required to stop your vehicle Regen IS NOT a safety feature Controller may stop regen without warning to protect itself or the battery it wont protect you Page 3 Kelly KBS Brushless Motor Controller User s Manual V 4 1 2 2 Features 1 Intelligence with powerful microprocessor 2 Synchronous rectification ultra low drop fast PWM to achieve very high efficiency 3 Electronic reversing 4 Voltage monitoring on 3 motor phases bus and power supply 5 Voltage monitoring on voltage source 12V and 5V 6 Current sense on all 3 motor phases 7 Current control loop 8 Hardware over current protection 9 Hardware over voltage protection 10 Configurable limit for motor curr
9. Kelly KBS Brushless Motor Controller User s Manual V 4 1 Kelly KBS Brushless Motor Controller User s Manual Devices Supported KBS24051 KBS48051 KBS24051E KBS48051E KBS24101 KBS48101 KBS36051 KBS48121 KBS24121 KBS72051 KBS36101 572101 KBS72121 Rev 4 1 Dec 2011 Kelly KBS Brushless Motor Controller User s Manual V 4 1 Contents Chapter 1 1 2 SIMIC Wa an E tua ued E EER 2 Chapter 2 Features and 3 24 General MUNCH ONS aaa 3 saree cares eae ce ag E 4 2 OOPS EIICALIONS jr crscmeasen 4 24 Name REGUIATON nates 5 Chapter Wiring and Installations reer eee eee etter teeta 6 3 1 Mounting the CON OMEN 6 3 2 Connections E EE E ATA 7 3 3 Installation Check Listir oror n T 10 Chapter 4 Programmable 12 DEA rey CIO LE EEEN S ESE 12 ict a se Par aa ncaa E E act 13 4S 56 14 15 ois ol 0 16 Chapter 5
10. arting point Suggestion Set according to the practical situation factory default is 10 5 Throttle Effective Ending Point Page 12 Kelly KBS Brushless Motor Controller User s Manual V 4 1 Value range 60 100 Functional description Set throttle effective ending point Suggestion Set according to the practical situation factory default is 90 6 Max Motor Current Value range 20 100 Functional description The max motor current is The Value Peak Current of the Controller Suggestion Factory default is 100 7 Max Battery Current Value range 20 100 Functional description Set max battery current so as to protect battery A lower value means a lower battery output current and better protective effect But excessively low value will affect acceleration Suggestion Factory default is 100 4 2 Step 2 1 Start up Delay Time Value range 0 0s 2 0s Functional description When power is on set delay time to wait for stabilization of B a higher value means a longer delay time Suggestion Set according to the practical situation factory default is 0 5s 2 Hall Sensor Type Value range 60 degree and 120 degree Functional description Set according to your motor hall sensor type Suggestion Set according to the practical situation 3 Control Mode Value range Torque Balanced Speed Functional description Set controller output mode Torque mode brings faster response of the load and good acceleration
11. e protection avoidance of loose clothing hair and jewelry Always use insulated tools 5 1 Cleaning Although the controller requires virtually no maintenance after properly installation the following minor maintenance is recommended in certain applications e Remove power by disconnecting the battery starting with battery positive e Discharge the capacitors in the controller by connecting a load such as a contactor coil resistor or a horn across the controller s B and B terminals e Remove any dirt or corrosion from the bus bar area The controller should be wiped with a moist rag Make sure that the controller is dry before reconnecting the battery e sure the connections to the bus bars if fitted are tight To avoid physically stressing the bus bars use two well insulated wrenches 5 2 Configuration You can configure the controller with a host computer through either an RS232 or USB port e Disconnect motor wiring from controller not connect B throttle and so The controller may display fault code but it doesn t affect programming or configuration e Use a straight through RS232 cable or USB converter provided by Kelly to connect to a host computer Provide gt 18V to PWR for a 24V controller provide gt 8V Wire power supply return supply negative to any RTN pin Download the free configuration software from http www kellycontroller com support php Caution e Make ce
12. ent and battery current 11 Support torque mode speed mode and balanced mode operation 12 Low EMC 13 LED fault code 14 Battery protection current cutback warning and shutdown at configurable high and low battery voltage 15 Rugged aluminum housing for maximum heat dissipation and harsh environment 16 Rugged high current terminals and rugged aviation connectors for small signal 17 Thermal protection current cut back warning and shutdown on high temperature 18 Configurable 60 degree or 120 degree hall position sensors 19 Support motors with any number of poles 20 Up to 40 000 electric RPM standard Optional high speed 70 000 ERPM Electric RPM mechanical RPM motor pole pairs 21 Support three modes of regenerative braking brake switch regen release throttle regen 0 5V analog signal variable regen 22 Configurable high pedal protection Disable operation if power up with high throttle 23 Current multiplication Take less current from battery output more current to motor 24 Easy installation 3 wire potentiometer will work 25 Standard PC Laptop computer to do programming No special tools needed 26 User program provided Easy to use No cost to customers 2 3 Specifications Frequency of Operation 16 6kHz e Standby Battery Current lt 0 5mA 5V Sensor Supply Current 40mA Controller supply voltage range PWR 18V to 90V for controllers rated equal or lower than 72V
13. ggestion Set according to the practical situation 3 Releasing Throttle Regen Mode and Max Allowed Regen Current Value range 0 20 Functional description Set the max allowed regen current in releasing throttle regen mode Suggestion Set according to the practical situation factory default is 0 4 Max Allowed Regen Current In Brake Switch Regen Mode Value range 5 50 Functional description Set the max allowed regen current in brake switch regen mode Page 15 Kelly KBS Brushless Motor Controller User s Manual V 4 1 Suggestion Set according to the practical situation factory default is 20 5 Max Regen Current Value range 20 100 Functional description Max regen current with max signal from brake sensor Suggestion Set according to the practical situation factory default is 100 6 Brake Sensor Type Value range No used 3 wire resistive pot hall active throttle Functional description Set brake sensor type Please choose Not Used if analog brake sensor isn t used You have to turn on brake switch to start regen then vary regen with the signal Suggestion Set according to the practical situation factory default is Not Used 7 Brake Sensor Starting Point Value range 0 40 Functional description Set brake sensor effective starting point Suggestion Set according to the practical situation factory default is 10 8 Brake Sensor Ending Point Value range 60 100 Functional description
14. r will report fault and not operate Suggestion Set according to the practical situation factory default is Enable 8 Releasing Brake High Pedal Disable Value range Enable and Disable Functional description If enabled the controller will detect the current pedal status when release the brake If throttle got effective output the controller will report fault and not operate Suggestion Set according to the practical situation factory default is Enable 4 3 Step 3 1 Motor Top Speed Value range 30 100 Functional description Limit top speed of the motor Suggestion Set according to the practical situation factory default is 100 2 Half Speed In Reverse Value range Enable and Disable Functional description If enabled the max reverse speed of the motor will be limited to half of the max forward speed Suggestion This function is available for firmware version 0103 or less Set according to the practical situation factory default is Disable 3 Boost Function Value range Enable and Disable Functional description Please see figure 4 3 Suggestion Set according to the practical situation factory default is Disable 4 Economy Function Value range Enable and Disable Functional description Please see figure 4 3 Suggestion Set according to the practical situation factory default is Disable Page 14 Kelly KBS Brushless Motor Controller User s Manual V 4 1 Configu
15. ration Pin Status Output Current Boost Economy J2 6 Max Current max Disable Disable xX 0 l_max 0 1 50 Disable Enable OFF 0e max Enable Disable OFF 0 1 60 Figure 4 3 Note Boost Function Economy Function and Half Current In Reverse can not be used at the same time 5 Half Current In Reverse Value range Enable and Disable Functional description If enabled the max output current will be limited to half at reversing Suggestion Set according to the practical situation factory default is Disable 6 ABS Value range Enable and Disable Functional description ABS function Suggestion This function is available for firmware version 0104 or later Set according to the practical situation factory default is Disable 7 Motor Top Speed In Reverse Value range 20 100 Functional description Limit max reverse speed of the motor Suggestion This function is available for firmware version 0104 or later Set according to the practical situation factory default is 100 4 4 Step 4 1 Regeneration Value range Enable and Disable Functional description If enabled the controller can do regen braking It will recover mechanical energy and charge back to battery Suggestion Set according to the practical situation 2 Brake Switch Regen Mode Value range Enable and Disable Functional description If enabled turn off throttle and turn on brake switch will start regen Su
16. rive reverse beeper lt 200mA Yellow Female Connector Pin Definition 15 Micro_SW Throttle switch input Gray 3 Throttle Throttle analog input 0 5V Dark Green 1 BRK2 12V Brake switch input or Motor temperature sensor input Raddle 20 RTN Signal return Black 8 Meter Current meter lt 200mA Dark Blue 13 BRK_SW Brake switch input Brown 4 5V 5V supply output lt 40mA Orange 2 BRK_AN Brake analog input 0 5V White 19 RTN Signal return Black Notes 1 All RTN pins are internally connected 2 Kelly Ammeter positive connects to 5V power supply of controller negative to Dark Blue wire 3 Switch to ground is active Open switch is inactive Caution Do not apply power until you are certain the controller wiring is correct and has been double checked Wiring faults will damage the controller Ensure that the B wiring is securely and properly connected before applying power The preferred connection of the system contactor or circuit breaker is in series with the B line All contactors or circuit breakers the B line must have precharge resistors across their contacts Lack of even one of these precharge resistors may severely damage the controller at switch on Page 8 V 4 1 BATTERY IKO 10W POLE J a a gt 2 lt PRECHARGE RESISTOR 3 2 2 1 Standard wiring of KBS controller Kelly KBS Brushless Motor Controller User s Manual
17. rogressively cut back motor drive power as battery voltage drops until it cuts out altogether at the preset Low Battery Voltage setting 3 Built in current loop and over current protection 4 Configurable motor temperature protection range 5 Current cutback at low temperature and high temperature to protect battery and controller The current begins to ramp down at 90 temperature shutting down at 100 C 6 controller keeps monitoring battery recharging voltage during regenerative braking progressively cutting back current as battery voltage rises then cutting off regen altogether when voltage goes too high 7 Maximum reverse speed is configurable to half of the maximum forward speed 8 RS232 port allows for configuration programming and software upgrades using the free Windows GUI with your PC 9 Provision of a 5 volt output to supply various kinds of sensors including Hall effect type 10 3 switch inputs which are activated by connection to Ground Default to throttle switch brake switch and reversing switch 11 analog 0 5V inputs that default to throttle input brake input and motor temperature input 12 Pulsed reverse alarm output 13 Main contactor driver Cutting off the power if any fault is detected 14 Current meter to display both drive and regen current Save shunt 15 Configurable boost switch Enables the maximum output power achievable if the switch is turned on
18. roller case temperature is above 90 C warning Current will be limited Reduce controller loading or switch Off until controller cools down 2 Clean or improve heatsink or fan 2 1 Motor did not start Motor did not reach 25 electrical RPM within 2 seconds of start up Hall sensor or phase wiring problem 2 2 Internal volts fault 1 Measure that B amp PWR are correct when measured to B or RTN 2 There may be excessive load on the 5V supply caused by too low a value of Regen or throttle potentiometers or incorrect wiring 3 Controller is damaged Contact Kelly about a warranty repair 2 3 Over temperature controller temperature has exceeded 100 C controller will be stopped but will restart when temperature falls below 80 C 2 4 xa aaan Throttle error at Throttle signal is higher than the preset dead zone at power up Power On Fault clears when throttle is released Page 18 V 4 1 Kelly KBS Brushless Motor Controller User s Manual V 4 1 3 1 Frequent reset May be caused by over voltage bad motor intermittent earthing problem bad wiring etc 3 2 ooa Internal reset May be caused by some transient fault condition like temporary over current momentarily high or low battery voltage This can happen during normal operation 3 3 moo ann Hall throttle is open When the throttle is repaired a restart will clear the or
19. rtain that the motor is disconnected before trying to run the Configuration Software Configuration software will be regularly updated and published on the website Please Update your Configuration Software regularly You must uninstall the older version before updating When setting Hall Sensor in GUI do not use Auto Check This has been deleted from the newer configuration software versions Page 17 Kelly KBS Brushless Motor Controller User s Manual Table 1 LED CODES Green LED Codes LED Code Explanation Solution Green Off No power or 1 Check if all wires are correct switched off 2 Check fuse and power supply Green On Normal operation Thats great You got solution On Green amp Red are both 1 Software still upgrading 2 Supply voltage too low or battery too high 3 The controller is damaged Contact Kelly about a warranty repair Red LED Codes LED Code Explanation Solution 1 2 on Over voltage error 1 Battery voltage is too high for the controller Check battery volts and configuration 2 Regeneration over voltage Controller will have cut back or stopped regen 3 This only accurate to 2 upon Overvoltage setting 1 3 Low voltage error 1 The controller will clear after 5 seconds if battery volts returns to normal 2 Check battery volts amp recharge if required 1 4 Over temperature 1 Cont
20. s KBS Configuration program allow users to set parameters according to the vehicle actual working environment so as to be at its best The default parameters of the controller are not recommended for all applications Make sure set the proper parameters before making any test to avoid danger 4 1 Step 1 1 Forward Switch Value range Enable and Disable Functional description If enabled throttle switch will be considered as Forward Switch Please see figure 4 1 Suggestion Set according to the practical situation factory default is Disable 2 Foot Switch Value range Enable and Disable Functional description If enabled and turn off foot switch controller will not operate Please see figure 4 1 Suggestion Set according to the practical situation factory default is Disable Configuration Pin Status Running Forward Switch Foot Switch J2 8 J2 9 Status OFF OFF Neutral ON OFF Forward Enable Disable OFF ON Back ON ON Neutral OFF xX Not operate Disable Enable ON OFF Forward ON ON Back xX OFF Forward Disable Disable ON Back Figure 4 1 3 Throttle Sensor Type Value range 3 wire resistive pot hall active throttle Functional description Set throttle sensor type Suggestion Set according to the practical situation factory default is 3 wire resistive pot 4 Throttle Effective Starting Point Value range 10 40 Functional description Set throttle effective st
21. short circuit fault 3 4 xaa paan Non zero throttle on Controller won t allow a direction change unless the direction change throttle or speed is at zero Fault clears when throttle is released 4 1 poon Regen or Start up Motor drive is disabled if an over voltage is detected over voltage at start up or during regen The voltage threshold detection level is set during configuration 4 2 ooo Hall sensor error 1 Incorrect or loose wiring or a damaged hall sensor 2 Also be caused by incorrect hall angle configuration 60 degree or 120 degree 4 3 nooo ooo Motor temperature has exceeded the configured over temperature maximum The controller will shut down until the motor temperature cools down The Red LED flashes once at power on as a confidence check and then normally stays Off 1 2 means the Red flashes once and after a second pause flashes twice The pause time between multiple flash code groups is two seconds Contact Us Kelly Controls LLC Home Page http Awww KellyController com E mail Support KellyController com Phone 01 224 637 5092 Page 19
Download Pdf Manuals
Related Search