Kelly KEB Controllers User Manual
Contents
1. TT T TT 12 Table 1 LED CODES acc ede eee ase t aa 13 Contact US cer te e emnt tes Uns Lb cet et nce Ps 15 Page 1 Kelly Ebike Brushless DC Motor Controller User s Manual V3 3 Chapter 1 Introduction 1 1 Overview This manual introduces the Kelly ebike brushless DC motor controllers features their installation and their maintenance Read the manual carefully and thoroughly before using the controller If you have any questions please contact the support center of Kelly Controls LLC Kelly s programmable KEB motor controllers provide efficient smooth and quiet controls for electric bicycles electric motorcycles scooters etc It outputs high taking off current and strictly limit battery current It can work with relative small battery but provide good acceleration and hill climbing 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 Ebike Brushless DC Motor Controller User s Manual V3 3 Chapter 2 Main 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 will2. Use well insulated tools Make sure the wire is connected correctly Turn the PWR switch on 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 controller ground The fault code will be detected automatically at restart 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 in a clear area It should have smooth acceleration and good top speed Page 11 Kelly Ebike Brushless DC Motor Controller User s Manual V3 3 Chapter 4 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 eye protection avoidance of loose clothing hair and jewelry Always use insulated tools 4 1 Cleaning Although the controller requires virtually no maintenance after properl
3. progressively 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 C case temperature shutting down at 100C 6 The 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 max forward speed 8 Configurable and programmable with a host computer though RS232 or USB Provide free GUI which can run on Windows XP 2000 Windows 7 and Vista recommend using Kelly standard USB to RS232 Converter 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 3 analog inputs 0 5V inputs that default to throttle input brake input and motor temperature input 12 Configurable boost switch Enables the maximum output power achievable if the switch is turned on 13 Configurable economy switch Limits the maximum current to half if the switch is turned on 14 Maximum re
4. Motor Controller Precharge Resistor I KO 10W Battery Fuse Main Contactor Pole LVAD T Diode 200V oo Key Switch Fuse JE Mi 0 5V Brake Pedal 7 Reverse Switch 0 5V Throttle BLDC Motor Please securely wire B before any other wiring Never put contactor or break on B Thermistor is optional item default to KTY84 130 NOTE Potentialmeter can be used to output 0 5V Figure 5 KEB controller standard wiring Battery voltage can be used for controller supply Page 10 Kelly Ebike Brushless DC Motor Controller User s Manual V3 3 3 2 3 Communication Port A RS232 port of controller is provided to communicate with host computer for calibration and configuration QO QQ Figure 6 standard RS232 interface 3 3 Installation Check List Before operating the vehicle complete the following checkout procedures 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
5. Kelly Ebike Brushless DC Motor Controller User s Manual V3 3 Kelly KEB Brushless Motor Controller User s Manual Devices Supported KEB48200X KEB48300X KEB48400X KEB48600 KEB72300X KEB72450X KEB72600X KEB72800X KEB72100 KEB72120E KEB84600X KEB84800X KEB84120E KEB48201X KEB48301X KEB48401X KEB48601 KEB72301X KEB72451X KEB72601X KEB72801X KEB72101 KEB72121E KEB84601X KEB84801X KEB84121E Rev 3 3 Dec 2014 Kelly Ebike Brushless DC Motor Controller User s Manual V3 3 Contents Chapter 1 UBIFOOHGIIO on Leoben up deo dede iubes enn Re de entree Mm em aca ae 2 desde es dac den Naas tical UE Ed LU ot LA TID ait 2 Chapter 2 Main Features and 3 2 1 General TU Holst Rv trt Ne dua sued bn EPUM Ve utc ta ta opi 3 ZRPUAITII me 4 2 3 Nate E T ian 4 ZR Mos P 5 Chapter 3 Wiring and Installation sssseeeeen 6 3 1 etisretn 2eoniel e e M 6 3 2 COMMECHONS een EE 8 3 2 1 Front Panel of KEB Motor Controller 8 3 2 2 Standard Wiring of KEB Motor 10 2 23 C mmunicaton POE oua Strat ho Lo ota c htm bue LM 11 3 3 Installation Check LISTS ees ett tto e tton tette tbe etes 11 Chapter 4 eld all a dede oer nts 12 GI ique TT 12 4 2
6. Motor Controller User s Manual V3 3 Contact Us Kelly Controls LLC Home Page http Awww KellyController com E mail Support KellyController com Phone 001 224 637 5092 Page 15
7. Operation 16 6kHz Standby Battery Current 0 5mA 5V Sensor Supply Current 40mA Page 4 Kelly Ebike Brushless DC Motor Controller User s Manual V3 3 Controller supply voltage range PWR 18V to 90V Supply Current PWR 150mA Configurable battery voltage range B Max operating range 18V to 1 25 Nominal Standard Throttle Input 0 5 Volts 3 wire resistive pot 1 4 Volts hall active throttle Analog Brake and Throttle Input 0 5 Volts Producing 0 5V signal with 3 wire pot Full Power Operating Temperature Range to 50C controller case temperature Operating Temperature Range 30C to 90C 100C shutdown controller case temperature Peak Phase Current 10 seconds 150A 550A depending on the model Continuous Phase Current Limit 60A 200A depending on the model Maximum Battery Current Configurable 2 4 Models The naming regulations of the Kelly KEB motor controller model KEB72300X L last letter means extended performance The eighth letter represents regeneration 0 non regen 1 with regen The sixth and seventh letters the max actual output power of controller 10 except letters 10 unit kW 10 represents 10kW The fourth and fifth letters represent nominal voltage The first three letters represent Kelly s electric bicycle motor controller Page 5 Kelly Ebike Brushless DC Motor Controller User s Manual V3 3 Chapter 3 Wiring and Installation 3 1 Mounting the Cont
8. and battery current Battery current limiting available doesn t affect taking off performance startup current can get more startup speed Low EMC LED fault code Battery protection current cutback warning and shutdown at configurable high and low battery voltage Rugged aluminum housing for maximum heat dissipation and harsh environment Rugged high current terminals and rugged aviation connectors for small signal Thermal protection current cut back warning and shutdown at high temperature Configurable 60 degree or 120 degree hall position sensors Support motors with any number of poles Up to 40 000 electric RPM standard Optional high speed 70 000 ERPM and ultra high speed 100 000 ERPM Electric RPM 2 mechanical RPM motor pole pairs Brake switch is used to start regen 0 5V brake signal is used to command regen current eSupport three modes of regenerative braking brake switch regen release throttle regen 0 5V analog signal variable regen Configurable high pedal protection the controller will not work if high throttle is detected at power on Current multiplication Take less current from battery output more current to motor Easy installation 3 wire potentiometer will work Current meter output Standard PC Laptop computer is used to do programming No special tools needed User program provided Easy to use No cost to customers 2 3 Specifications Frequency of
9. e B battery negative A Output U 1 A phase B Output V 2 B phase C Output W 3 C phase Figure 4 The connecting diagram of J2 mor J2 Pin Definition e LOL NS 1 PWR Controller power supply O 11 e RTN Signal return or power supply ground 2 3 RTN Signal return 4 12V high level brake and motor temperature input 5 Throttle analog input 0 5V ex 6 Brake analog input 0 5V 7 5V 5V supply output 40mA 8 Micro SW Throttle switch input 9 Reversing switch input 10 Brake switch input Page 8 Kelly Ebike Brushless DC Motor Controller User s Manual V3 3 11 Hall phase C 12 Hall phase B 13 Hall phase A 14 RTN Signal return Notes 1 All RTN pins are internally connected is internally connected to B 2 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 in 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 9 Kelly Ebike Brushless DC Motor Controller User s Manual V3 3 3 2 2 Standard Wiring of KEB
10. lder version before updating When setting Hall Sensor Type in GUI do not use Auto Check This has been deleted from the newer configuration software versions Page 12 Kelly Ebike Brushless DC Motor Controller User s Manual Table 1 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 That s great You got solution Green amp Red are both On 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 unu 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 a aan 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 a aana Over temperature 1 Controller 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 n Motor did not start Motor did not reach 25 electrical RPM within 2 second
11. n happen during normal operation 3 3 ano nun Hall throttle is When the throttle is repaired a restart will clear the open or fault short circuit 3 4 suum soon Non zero throttle Controller won t allow a direction change unless the on direction throttle or speed is at zero Fault clears when change throttle is released 4 1 nonn n Regen or Start up Motor drive is disabled if an over voltage is over voltage detected at start up or during regen The voltage threshold detection level is set during configuration 4 2 anan oon 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 anna Motor Motor temperature has exceeded the configured over temperature maximum The controller will shut down until the motor temperature cools down 4 4 annn Motor locked rotor When in locked rotor condition the max output anon phase current of the motor will be limited to 90 of previous current Once this problem disappears the fault will clear and the max output phase current will return to normal 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 time between two flashes is 0 5 second The pause time between multiple flash code groups is two seconds Page 14 Kelly Ebike Brushless DC
12. roller The controller can be oriented in any position which should be as clean and dry as possible if necessary shielded with a cover to protect it from water and 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 thermal conductive material to 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 holes dimensions are shown in Figure 1 and 2 ro Se Se ee eee a o J C m rm D umi vens PE NNNM a ee a 130 146 Height 62 millimeters Figure 1 KEB KEB X mounting holes dimensions dimensions in millimeters Page 6 Kelly Ebike Brushless DC Motor Controller User s Manual V3 3 Ww ea Height 62 millimeters Figure 2 KEB E mounting holes dimensions dimensions in millimeters Page 7 Kelly Ebike Brushless DC Motor Controller User s Manual V3 3 3 2 Connections 3 2 1 Front Panel of KEB Motor Controller Five metal bars and a 14pin rugged connector are provided for connecting to the battery motor and control signals in the front of the controller shown as Figure 3 wN B B B aes EE 10 12 RS232 Figure 3 Front panel of KEB motor controller B battery positiv
13. s of start up Hall sensor or phase wiring problem 2 2 ono 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 The controller will be stopped but will restart when temperature falls below 80 C 2 4 uu anon Throttle error at 1 Throttle signal is higher than the preset dead power up zone at Power On Fault clears when throttle is released 2 Setthrottle model as Hall Active throttle in Page 13 Kelly Ebike Brushless DC Motor Controller User s Manual V3 3 GUI if you use that throttle type 3 1 Hun au Frequent reset 1 The controller will stop driving when detects too many resets 2 Mostly because of B or return wiring Use the heavier and cleaner return wires For dual controllers bond B of both controllers together with a heavy cable or copper strip 3 May be caused by over current Set max current to be lower 4 Arestart will clear the fault 5 Please contact Kelly if it happens repeatedly 3 2 Hun uu Internal reset May be caused by some transient fault condition like a temporary over current momentarily high or low battery voltage This ca
14. verse power is configurable to half power 15 Enhanced regen brake function A novel ABS technique provides powerful and smooth regen 16 Configurable 12V brake signal input instead of motor temperature sensor 17 Optional joystick throttle A bi symmetrical 0 5V signal for both forwarding and reversing 18 Configurable motor over temperature detection and protection with the recommended thermistor KTY84 130 19 3 hall position sensor inputs Open collector pull up provided 20 Optional supply voltage 8V 30V Caution Hegeneration has braking effect but does not replace the function of a mechanical brake A mechanical brake is required to stop your vehicle Hegen IS NOT a safety feature Controller may stop regen without warning to protect itself or the battery it won t protect you Page 3 Kelly Ebike Brushless DC Motor Controller User s Manual V3 3 2 2 Features Specially designed for electric bicycle and scooter Intelligence with powerful microprocessor Synchronous rectification ultra low drop fast PWM to achieve very high efficiency Electronic reversing Voltage monitoring on 3 motor phases bus and power supply Voltage monitoring on voltage source 12V and 5V Current sense on all 3 motor phases Current control loop Hardware over current protection Hardware over voltage protection Support torque mode speed mode and balanced mode operation Configurable limit for motor current
15. y installation the following minor maintenance is recommended in certain applications Remove power by disconnecting the battery starting with battery positive Discharge the capacitors in the controller by connecting a load such as a contactor coil or a horn across the controller s B and B terminals Remove any dirt or corrosion from the bus bar area The controller should be wiped down with a moist rag Make sure that the controller is dry before reconnecting the battery Make sure the connections to the bus bars if fitted are tight To avoid physically stressing the bus bars use two well insulated wrenches 4 2 Configuration You can configure the controller with a host computer through either an RS232 or USB port e Disconnect motor wiring from controller Do not connect B throttle and so on The controller may display fault code in some conditions but it doesn t affect programming or configuration e Use straight through RS232 cable or USB Converter provided by Kelly to connect to a host computer Provide 18V 90V to PWR Wire power supply return to any RTN pin Download the free configuration software from http www kellycontroller com support php Caution Make certain 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 o
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