Kelly Motor Controller - Ki
Contents
1. with powerful microprocessor Synchronous rectification ultra low drop fast PWM to achieve very high efficiency Current limit and torque control Battery current limiting available doesn t affect taking off performance More startup current can get more startup speed Low EMC sl ED fault code helps users to debugging Battery protection current cut back shutdown and warning at low battery e Rugged aluminum housing for maximum heat dissipation eThermal protection Current cutback at low temperature and high temperature to protect battery and controller Compatible with 60 degree or 120 degree hall position sensor e Any number of poles supported Up to 40000 electric RPM electric RPM mechanical RPM motor pole pairs Brake switch is used to start regen 0 5V brake signal is used to command regen current Three modes of regen brake switch regen release throttle regen 0 5V signal regen e High pedal protection Disable operation if power up with non zero throttle e Current multiplication Take less current from battery output more current to motor e Easy installation 3 wire potentiometer will work 2 3 Specifications Frequency of Operation 16 6KHz Standby Battery Current lt 1mA 5V Sensor Supply Current 40mA Supply Voltage PWR 18V to 90V Supply Current PWR 150mA Operating Voltage B 18V to 1 25 Nominal sAnalog Brake and Throttle Input 0 5 Volts Producing 0 5V signa2. 3 The controller is damaged Please contact Kelly for warrantee Red LED Codes LED Code Explanation Solution 1 2 a ana Over voltage error 1 Battery voltage is higher than max operating voltage of the controller Please check the battery voltage and configuration 2 Over voltage at regeneration Controller will cut back or stop regeneration 3 Please note there could be 2 error with Overvoltage setting 1 3 a ana Low voltage error 1 The controller will attempt to clear the fault code automatically after 5 second if battery voltage returns to normal 2 Check the battery voltage 3 Charge battery if necessary 1 4 a nooo Over temperature warning The controller temperature is over 90 C The controller will cut back current in the case Stop or reduce output to ensure the temperature fall 2 Improve heat sink or airflow 2 1 no a Motor fails to start Motor hasn t reached 25 electrical RPM after 2 seconds from starting Most likely the hall or phase wiring problem 2 2 no no Internal voltage fault 1 Check if the B and PWR voltage are correct refer to B or RTN Could be PWR voltage low 2 Please check load on 5V supply Could be high load on 5V Incorrect pot wiring can load it heavily 3 The controller is damaged Please contact Kelly for warrantee 2 3 an HER Over temperature 1 When controller s temperature is ove
3. Kelly Ebike Brushless DC Motor Controller User s Manual V 3 1 Kelly KEB Brushless Motor Controller User s Manual Devices Supported KEB48220 KEB48300 KEB48400 KEB48600 KEB72330 KEB72450 KEB72600 KEB72800 KEB48221 KEB48301 KEB48401 KEB48601 KEB72331 KEB72451 KEB72601 KEB72801 Rev 3 1 Mar 2008 Kelly Ebike Brushless DC Motor Controller User s Manual V 3 1 Contents Chapter Wl dee et 2 RES SR EE N RE IE 2 Chapter 2 Main Features and Gpechfcations ss ee ee ee ee ee ee ee ee ee ee 3 SCENE 3 2 2 EN nenene REEERE EREEREER EEE EEEE SCTE ETE TTT E TET EEES 4 2 3 DOES CINCALONG E 4 24 Models Ee cc ccccccccccccccnnntete 5 Chapter 3 Wiring and Installatnon EE Ee ee ee ee ee ee ee ee ee ee ee ee 5 3 1 Mounting ine Gornroll E 5 3 2 Be sisie AE EER DE 7 3 3 Installation Check LIST ss RNEER GE Ge 10 Chapter E Ee 11 41 e ANN EE 11 4 AE OIG AO rade EE EER EE EE EER EER RR Ee GEGEE Ee RAS 11 Table 1 LED GODE Ses sesde eed ds ee EA aaa A AAEE 12 Contact de OE ee EEEE 14 Page 1 Kelly Ebike Brushless DC Motor Controller User s Manual V3 1 Chapter 1 Introduction 1 1 Overview The manual introduces Kelly ebike brushless DC motor controllers features installation and 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 quite
4. and programmable with RS 232 Software upgradeable Windows GUI provided 9 Provide 5V sensor supply 10 3 switch inputs Default to throttle switch brake switch and reverse switch Closing to ground is to activate 11 3 analog inputs 0 5V Default to throttle input brake input and motor temperature input 12 Configurable boost switch Output can arrive at the maximum current if the switch is enabled and turned on 13 Configurable turbo switch Limit max power to half if the switch is enabled and turned on 14 Configurable max reverse power to half 15 Enhanced regen brake function Novel ABS technique provides powerful and smooth regen 16 Configurable 12V brake signal input instead of motor temperature sensor 17 Optional joystick throttle Single 0 5V signal for both forwarding and reversing 18 Thermal overload detection and protection to safeguard the motor from over temperature with recommendedSilicon temperature sensors KTY83 122 19 3 hall position sensor inputs Open collector pull up provided 20 Optional supply voltage 8V 30V Caution Regeneration has braking effect but can t replace mechanical brake Mechanical brake is required to stop your vehicle Regen isn t a safety feature Controller may stop regen to protect itself not you Page 3 Kelly Ebike Brushless DC Motor Controller User s Manual V 3 1 2 2 Features Specially designed for electric bicycle and scooter elntelligence
5. ch is inactive Caution Make sure all connections are correct before applying power Otherwise it may damage the controller Please securely wire B before applying power It s preferred to place contactor or breaker on B Please place precharge resistor on any breaker It can cause damage without it Page 8 Kelly Ebike Brushless DC Motor Controller User s Manual V 3 1 3 2 2 Standard Wiring of KEB Motor Controller Precharge Resistor IKO LOW Battery It 41 0 5V Brake Pedal how S e m OO Please securely wire B before any other wiring Never put contactor or break on B Thermistor is optional item default to KTY83 122 NOTE Potentialmeter can be used to output SV Figure 4 KEB controller standard wiring Battery voltage can be used for controller supply Page 9 Kelly Ebike Brushless DC Motor Controller User s Manual V 3 1 3 2 3 Communication Port A RS232 port of controller is provided to communicate with host computer for calibration and configuration oT pene oe O O Oo Oo Q Figure 5 standard RS232 interface 3 3 Installation Check List Before operating the vehicle complete the following checkout procedures Use LED code as a reference The LED codes are listed in Table 1 Caution e Put the vehicle up on blocks to get the drive wheels off the ground before beginning these tests e Do not allow anyone to stand directly in front of or behind the vehicle du
6. controls for electric bicycle electric motorcycle scooter 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 PWM to achieve efficiency 99 In most cases Powerful microprocessor brings in comprehensive and precise control to the controllers It also allows users to set parameters conduct tests and obtain diagnostic information quickly and easily Page 2 Kelly Ebike Brushless DC Motor Controller User s Manual V 3 1 Chapter 2 Main Features and Specifications 2 1 General functions 1 Extended fault detection and protection LED flashing code indicates fault sources 2 Monitoring battery voltage It will stop driving if battery voltage is too high It will cut back then stop driving if voltage is going too low 3 Built in current loop and over current protection 4 Controller temperature measurement and protection 5 Cutting back current at low temperature and high temperature to protect battery and controller The current will ramp down quickly if controller temperature is higher than 90 C and shut down at 100 C Low temperature current ramping down usually starts at 0 C 6 The controller keeps monitoring voltage during regen It will cut back current or stop regen if voltage is too high 7 Configurable to limit max reverse speed to half of max forward speed 8 Configurable
7. l with 3 wire pot Full Power Operating Temperature Range 0 C to 50 C controller case temperature Operating Temperature Range 30 C to 90 C 100 C shutdown controller case temperature Peak Phase Current 30 seconds 100 300A depending on model Continuous Phase Current Limit 50A 150A depending on model Maximum Battery Current Configurable Page 4 Kelly Ebike Brushless DC Motor Controller User s Manual V 3 1 2 4 Models The naming regulations of the Kelly KEB motor controller model KEB72 330 The eighth letter represents regeneration 0 non regeneration 1 with regeneration The sixth and seventh letters represent the rated output power divided by 10 unit kw The fourth and fifth letters represent the max voltage The first three letters represent Kelly s electric bicycle motor controller Chapter 3 Wiring and Installation 3 1 Mounting the Controller The controller can be oriented in any position as clean and dry as possible or shield 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 gel or other thermal conductive material to contact surface will enhance thermal performance Sufficient heat sink and airflow are required for high power application The case outline and mounting holes dimensions are shown in Figure 1 Page 5 Kelly Ebike Brushle
8. ou may set max voltage threshold with GUI 4 2 annan op Hall sensor signal 1 Most likely caused by incorrect hall wiring to error wrong pin or loose wire 2 Intermittent or damaged hall sensor 3 Double check hall angle setting 60 degree or 120 degree 4 3 aana opp Motor over 1 The motor temperature is higher than configured temperature max temperature Controller will shut down and wait for motor temperature dropping 2 Change the temperature setting with configuration program The Red LED flashes once at power on then keeps off for normal operation 1 2 means it flashed once then flashes twice after 1 second The time between two flashes is 0 5 second The pause time between one error code and another error code is 2 second Page 13 Kelly Ebike Brushless DC Motor Controller User s Manual V 3 1 Contact Us Kelly Controls LLC Home Page http www newKellyController com E mail Support KellyController com Phone 001 224 637 5092 Page 14
9. r 100 C it will stop driving in order to protect itself 2 Stop driving and wait for temperature fall The controller will restart if temperature drops below 80 C Page 12 Kelly Ebike Brushless DC Motor Controller User s Manual V3 1 2 4 aa sono Throttle error at 1 The throttle signal is higher than configured power up dead zone at power on 2 The fault will disappear if restarts or releases throttle 3 1 ooo n Frequent reset 1 The controller will stop driving after detecting 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 heavy cable or copper strip 3 Could be over current protection May set max current lower 4 Restarting will clear the error 5 Please contact Kelly if it happens repeatedly 3 2 moo HA Internal reset Reset caused by over current high battery voltage or low supply voltage It is normal if occurs occasionally 3 4 ana paan Throttle isn t zero The controller won t change drive direction if when try to throttle isn t zero Also it won t change direction at change direction high speed The controller will wait throttle and speed close to zero before changing direction 4 1 mond n Over voltage at The controller won t drive motor if detects startup or overvoltage at power up It will cut back regen regeneration current or stop regen at overvoltage Y
10. ring the checkout e Make sure both the PWR switch and the brake are off e Use well insulated tools e Make sure the wire is connected correctly e Turn the PWR switch on The LED should blink then keep on when the controller operates normally If this does not happen check continuity of the PWR and controller ground e The fault code will be detected automatically at restarting e With the brake switch open select a direction and operate the throttle The motor should spin in the selected direction Please verify wiring and voltage if it doesn t operate Also check fuse The motor should run faster with increasing throttle If not refer to Table 1 LED code and correct the fault according to the code e Take the vehicle off the blocks and drive it in a clear area It should have smooth acceleration and good top speed Page 10 Kelly Ebike Brushless DC Motor Controller User s Manual V3 1 Chapter 4 Maintenance There are no user serviceable parts inside the controllers Do not attempt to open the controller or you will damage it However clearing the controller exterior periodically should be necessary The controller is inherently a high power device When working with any battery powered vehicle proper safety precautions should be taken These include but are not limited to proper training wearing eye protection avoiding loose clothing and jewelry and using insulated tools 4 1 Cleaning Although the cont
11. roller requires virtually no maintenance after properly installation the following minor maintenance is recommended in certain applications e Remove power by disconnecting the battery e Discharge the capacitors in the controller by connecting a load such as a contactor coil or a horn across the controllers B and B terminals e Remove any dirt or corrosion from the bus bar area The controller should be wiped down with a moist rag Be sure it is dry before reconnecting the battery e Make sure the connections to the bus bars are tight Use two wrenches for this task in order to avoid stressing the bus bars the wrenches should be well insulated 4 2 Configuration You can configure the controller with a host computer through RS232 e Use straight RS232 cable connecting the 9pin connector on face penal to a host computer Provide 18V to 90V to PWR Wire power supply ground to any RTN pin e Do not connect B throttle and so on The controller may display fault code but it doesn t affect programming or configuration Page 11 Kelly Ebike Brushless DC Motor Controller User s Manual Table 1 LED CODES LED Code Explanation Solution Green Off No power or not 1 Check if all wires are correct operating 2 Check fuse and power supply Green On Normal operation That s great You got solution Green and Red LED Keep On 1 Software is upgrading 2 Supply voltage is too low or battery is too high
12. ss DC Motor Controller User s Manual V 3 1 Ao Tu E bo DE PL D __ a 130 146 Height 62 millimeters Figure 1 mounting holes dimensions dimensions in millimeters Page 6 Kelly Ebike Brushless DC Motor Controller User s Manual V 3 1 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 2 rai N B B B Ld dei J2 RS232 Figure 2 Front panel of KEB motor controller B battery positive B battery negative A Output U 1 A phase B Output V 2 B phase C Output W 3 C phase Figure 3 The connecting diagram of J2 E ZO 10 h N J2 Pin Definition g IR O 1 PWR Controller power supply 9 1 3 12 3 2 RTN Signal return or power supply ground O 13 O O 3 RTN Signal return 8 O 4 4 Motor temperature input or 12V brake input A O C 5 Throttle analog input 0 5V Ac Brake analog input 0 5V J E 5 ee 7 SV 5V supply output lt 40mA 8 Micro SW Throttle switch input KE Page 7 Kelly Ebike Brushless DC Motor Controller User s Manual V 3 1 9 Reverse switch input 10 Brake switch input 11 Hall phase C 12 Hall phase B 13 Hall phase A 14 RTN Signal return Notes 1 All RTN pins are internally connected RTN is internally connected to B 2 Switch to ground is active Open swit
Download Pdf Manuals
Related Search