Kelly KBS Brushless Motor Controller User`s Manual Devices
Contents
1. 78 Height 41 millimeters Figure 1 mounting hole dimensions dimensions in millimeters Page 6 Kelly KBS Brushless Motor Controller User s Manual V1 1 3 2 Connections 3 2 1 Pin definition of KBS Controller 5 Orange 5V 21 Black Hall Connector 14 6 11 Deep Blue Black Dark Gray 1d REV RTN Green LED Do y Blue 1a RLY CTR 10 Male Connector Pink Yellow PWR ALARM 15 3 1 Tei Gray Dark Green Reddle fh fh fh ACC TPS AN BRK2 420 8 13 A A RK Tack Dark Blue Brown boo RTN METER BRK 4 2 19 Orange White Black Female Connector 5y BRK_AN RTN Figure 2 connector pin definition diagram 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 Male Connector Pin Definition 14 REV Reverse switch input Dark Blue 6 RTN Signal return or power supply return Black 11 Green LED Running indication Dark Gray 12 Red LED Fault code White Page 7 Kelly KBS Brushless Motor Controller User s Manual V1 1 9 RLY_CTR Main contactor driver lt 200mA Blue 7 PWR Controller power supply input Pink 10 Alarm To drive reverse beeper lt 200mA Yellow Female Connector Pin Definition 15 ACC Throttle switch input Gray 3 TPS_AN Throttle an2. 11 3 analog inputs 0 5V Default to throttle input brake input and motor temperature input 12 Reverse alarm output Recirculation diodes provided 13 Main contactor driver Cut off the power if any fault detected 14 Current meter to display both drive and regen current Save shunt 15 Configurable boost switch Output the maximum current achievable if the switch is enabled and turned on 16 Configurable turbo switch Limiting max power to half if the switch is enabled and turned on 17 Configurable max reverse power to half 18 Enhanced regen brake function Novel ABS technique provides powerful and smooth regen 19 Configurable 12V brake signal input in lieu of motor temperature sensor 20 Optional joystick throttle Single 0 5V signal for both forward and reversing 21 Motor over temperature detection and protection with recommended thermistor 22 3 hall position sensor inputs Open collector pull up provided 23 Optional supply voltage 8V 30V Caution Regeneration has braking effect but cant replace mechanical brake Mechanical brake Ze required to stop your vehicle Regen isnt a safety feature Controller may stop regen to protect itself not you Page 3 Kelly KBS Brushless Motor Controller User s Manual V1 1 2 2 Features 1 Intelligence with powerful microprocessor 2 Synchronous rectification ultra low drop fast PWM to achieve very high efficiency 3 Current limit and torque con
3. 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 la aan 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 aana Over temperature 1 The controller temperature is over 90 C The warning 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 ma m 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 pa nn 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 oo nnna Over temperature 1 The controller temperature is over 100 C Controller stops driving in the case 2 Stop driving and wait for temperature fall The co Page 13 Kelly KBS Brushless Motor Controller User s Manual V1 1 ntroller will restart if temperature drop
4. Kelly KBS Brushless Motor Controller User s Manual V1 1 Kelly KBS Brushless Motor Controller User s Manual Devices Supported KBS24051 KBS24101 KBS24121 KBS36051 KBS36101 KBS48051 KBS48101 KBS48121 KBS72051 KBS72101 KBS72121 Rev 1 1 Jan 2009 Kelly KBS Brushless Motor Controller User s Manual V1 1 Contents Kelly KBS Brushless NOU scree 0 ut BEE 0 EE E 1 Chapter 1 Introduchon nnen nennen nnne 2 lf Ka EE 2 Chapter 2 Features and Gpecfcations 3 SEENEN ee 3 22 Eeer 4 23 SS CUNARD NS arated hae a a A E 4 24 Name e oc cc seater cece cesses esos ec eia deae daa E eE EGA A NES Eeen adaa 5 Chapter 3 Wiring and Installaton 6 3 1 Mounting the el EE 6 3 2 ONIN G CHOI E 7 3 2 Installation Check E E 10 Chapter 4 Ee EE e 12 a EO GYE aLe ac eccceseceeclousesteg eset ends E A E E E recy ae ceesverceeseastecessx 12 4 2 Configura E 12 Tabl EE 13 Green LED EE eege Bee 13 Red KEE tege EE 13 ME US ssrin aaa iaaa EEEO ARRE 15 Page 1 Kelly KBS Brushless Motor Controller User s Manual V1 1 Chapter 1 Introduction 1 1 Overview The manual introduces Kelly Small BLDC motor controller features installation and maintenance Read the manual carefully and thoroughly before use 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 quite controls for electric motorcycle golf cart go cart as well as
5. alog input 0 5V Dark Green 1 BRK2 12V Brake switch input or Motor temperature sensor input Reddle 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 Recirculation diodes are provided in the controller to PWR for alarm and Contactor coil driver 3 Kelly Ampmeter positive connect to 5V power supply of controller negative to Dark Blue wire 4 Switch to ground is active Open switch is inactive Caution Make sure all connections are correct before apply 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 V1 1 Kelly KBS Brushless Motor Controller User s Manual 3 2 2 Wiring of KBS Controller 3 2 2 1 Standard wiring of KBS controller PRECHARGE RESISTOR LKO LOW BATTERY zt POLE g 08 INT amuoa 3 00 g UO yeaaq ao 207IEIUOD pnd 19 us TUNA AIO ue arojag g anm APMdas ased AE nchno o3 pas aq uw maupuan LON aoa 21810 ASO LO pauo Jau AT Yitlg gt CETT UD xx A y CT1PR x snI VT Img Ay 1090 OTA Figure 3 KBS controller standard wiring Battery voltage can be used fo
6. e any dirt or corrosion from the bus bar area The controller should be wiped 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 or USB port e Use straight through RS232 cable or USB converter provide by Kelly to connect the D9 connector to a host computer Provide gt 18V to PWR 24V controller only provide gt 8V Wire power supply return 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 Download and setup the configuration software http www newkellycontroller com support php Page 12 Kelly KBS Brushless Motor Controller User s Manual Table 1 LED CODES Green LED Codes V1 1 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 Thats great You got solution Green and Red LED 1 Software is upgrading Keep On 2 Supply voltage too low or battery too high 3 The controller is damaged Please contact Kelly for warrantee Red LED Codes LED Code Explanation Solution 1 2 le on Over voltage error
7. industry motor speed or torque control 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 KBS Brushless Motor Controller User s Manual V1 1 Chapter 2 Features and Specifications 2 1 General functions 1 Extended fault detection and protection LED flashing for fault code 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 Current cutback at low temperature and high temperature to protect battery and controller The current will ramp down quickly if controller temperature is higher than 90C and shutdown at 100C Low temperature current ramping down usually starts at OC 6 The controller keeps monitoring voltage during regen It will cut back current then cut off regen if voltage is going too high 7 Configurable to limit max reverse speed to half of max forward speed 8 Configurable and programmable with RS 232 Software upgradeable Windows GUI provided 9 Provide 5V sensor supply 10 3 switch inputs Close to ground to activate Default to throttle switch brake switch and reverse switch
8. mal 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 14 Kelly KBS Brushless Motor Controller User s Manual Contact Us Kelly Controls LLC Home Page http www newKellyController com E mail Support KellyController com Phone 01 224 637 5092 Page 15 V1 1
9. r controller supply Page 9 Kelly KBS Brushless Motor Controller User s Manual V1 1 3 2 2 2 Optional wiring of KBS controller The output signal of the pin is for 5V current meter From Controller SV voltmeter Meter Figure 4 wiring of curretn meter pin The 12V input signal of the pin supplies the second braking function of the controller BRK2 Reddle oS 12V Vechile supply From Controller Break Switch RIN 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 o err O eee Figure 6 RS232 Interface 3 3 Installation Check List Before operating the vehicle complete the following checkout procedure Use LED code as a reference 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 Do not allow anyone to stand directly in front of or behind the vehicle during the checkout e 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 V1 1 e Make sure the wire is connected correctly e Turn the PWR switch on The LED should blink then keeps on when the controller operates normally If this does not happen check continuity of the PWR and return e The fault code will be detected a
10. rating Temperature Range 0 C to 50 C controller case temperature Operating Temperature Range 30 C to 90 C 100 C shutdown controller case temperature Motor Current Limit 1 minute 50A 120A depending on model Motor Current Limit continuous 20A 50A depending on model Max Battery Current Configurable Page 4 Kelly KBS Brushless Motor Controller User s Manual V1 1 2 4 Name Regulation The name regulation of Kelly BLDC motor controllers KBS48101 Page 5 The eighth letter represents regeneration 0 non regeneration 1 with regeneration The sixth and seventh letters represent the max current divided by 10 The fourth and fifth letters represent nominal voltaae The first three letters represent Kelly s low power brushless motor controller Kelly KBS Brushless Motor Controller User s Manual V1 1 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 hole dimensions are shown in Figure 1 4 ee Leg
11. s below 80 C 2 4 xa aaan Throttle error at 1 The throttle signal is higher than configured dead power up zone at power on 2 The fault will disappear if restart or release throttle 3 1 noo n Frequent reset 1 It can be caused by over current bad motor bad ground wiring or so 3 2 Don op Internal reset Reset caused by over current high battery voltage or low supply voltage It is normal if occurs occasionally 3 4 moo paan Throttle isn t zero The controller won t change drive direction if throttle when try to change isn t zero Also it won t change direction at high direction speed The controller will wait throttle and speed close to zero before change direction 4 1 moon n Over voltage at The controller won t drive motor if detect overvoltage startup or at power up It will cut back regen current or stop regeneration regen at overvoltage You may set max voltage threshold with GUI 4 2 Donn 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 gaga opp Motor over 1 The motor temperature higher than configured max temperature temperature Controller will shutdown and wait for motor temperature drops 2 Can change the temperature setting with configuration program The Red LED flashes once at power on then keeps off for nor
12. trol 4 Battery current limiting available doesn t affect taking off performance Low EMC LED fault code helps user debugging NOOO Battery protection current cut back shutdown and warning at high or low battery Thermal enhanced rugged aluminum housing Rugged connectors Thermal protection current cut back on low temperature and high temperature to protect battery and controller 10 Configurable 60 degree or 120 degree hall position sensor 11 Support any number of poles 12 Up to 40000 electric RPM Electric RPM mechanical RPM motor poles 13 Three modes of regen brake switch regen release throttle regen 0 5V signal regen 14 15 16 High pedal protection Disable operation if power up with non zero throttle Current multiplication Take less current from battery output more current to motor Easy installation 3 wire potentiometer will work 17 KBS high speed optional Up to 70000 electric RPM 2 3 Specifications Frequency of Operation 16 6kHz Standby Battery Current lt 1mA 5V Sensor Supply Current 40mA e Supply Voltage PWR 18V to 90V for controllers rated equal or lower than 72V 8V to 30V for 24V controller e Supply Current PWR 150mA Operating Voltage B 18V to 1 25 Nominal Voltage Analog Brake and Throttle Input 0 5 Volts Can use 3 wire pot to produce 0 5V signal Reverse Alarm Main Contactor Coil Driver Meter lt 200mA Full Power Ope
13. utomatically at restart 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 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 Take the vehicle off the blocks and drive it in a clear area It should have smooth acceleration and good power Page 11 Kelly KBS Brushless Motor Controller User s Manual V1 1 Chapter 4 Maintenance There are no user serviceable parts inside the controllers Do not attempt to open the controller Or will void warranty However cleaning 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 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 Remov
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