KHB Controllers User Manual
Contents
1. e EI 30 S EE 1 6 4 e i 4t My uL E ri EI u Ewa ii rly E a N 29 174 ECC Height 84 millimeters Length 218 millimeters Figure 1 KHB mounting holes dimensions dimensions in millimeters Controller models with above dimension KHB12151 KHB12201 KHB12251 KHB12301 KHB12401 KHB14201 KHB72601 Kelly KHB HP High Power Brushless Motor Controller User s Manual V 4 4 162 Height 84 millimeters Length 286 millimeters Figure 2 KHB mounting holes dimensions dimensions in millimeters Controller models with above dimension KHB72701 KHB72101 KHB12601 KHB12801 KHB14301 KHB14401 Kelly KHB HP High Power Brushless Motor Controller User s Manual V 4 4 Height 84 millimeters Length 368 millimeters Figure 3 KHB mounting holes dimensions dimensions in millimeters Controller models with above dimension KHB14601 Kelly KHB HP High Power Brushless Motor Controller User s Manual V 4 4 The case outline and mounting holes dimensions of Controllers 194 183 BEE Height 78 5 millimeters Figure 4 HP mounting holes dimensions dimensions in millimeters 10 Kelly KHB HP High Power Brushless Motor Controller User s Manual V 4 4 3 2 Connections 3 2 1 Front Panel and back panel of Motor Controller Five metal bars in front panel and2. 20 4 2 Config ralloris ssi etate terere ie nep toners enr tdv er etta 20 Table T CODES deut edu e eat 21 Lon aere cute Non east cde d m utu Lese cds 23 Kelly KHB HP High Power Brushless Motor Controller User s Manual V 4 4 Chapter 1 Introduction 1 1 Overview This manual introduces the Kelly high power BLDC 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 motor controllers provide high efficient smooth and quiet controls for electric motorcycles forklifts hybrid vehicles electric vehicles and electric boats 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 A 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 Kelly KHB HP High Power Brushless Motor Controller User s Manual V 4 4 Chapter 2 Features and Specifications 2 1 General functions 1 Extended fault detection and protection The LED flashing pattern indicates the fault sources Green LED indicates normal operation Controller will shut down in some fault conditions 2 Monitoring battery voltage
3. osos 00000 Figure 12 standard RS232 Interface 3 3 Mounting the Capacitor for HP Motor Controller The capacitor 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 The outline and mounting holes dimensions of the capacitor are shown in Figure 13 uU in ru C C Height 75 millimeters Figure 13 Capacitor mounting holes dimensions dimensions in millimeters 17 Kelly KHB HP High Power Brushless Motor Controller User s Manual V 4 4 3 4 Connections 3 4 1 Front Panel and back panel of Capacitor Two metal bars in front panel and two in back panel are provided for connecting to the battery and HP BLDC controller shown as Figure 14 and Figure 15 Figure 14 Front Panel of Capacitor battery positive B battery negative Figure 15 Back Panel of Capacitor battery positive B battery negative 18 Kelly KHB HP High Power Brushless Motor Controller User s Manual V 4 4 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 line All contactors or circuit breakers in the B line must have prec
4. Sura iue g 310225 ased TEUSIS 45 0 dino gra rdw pure pua NTH PUE Az TEuzrs PO se pasn aq 12j2uenua 0d Nz 0 ILON omg 2519A2 Lf As 0 INSMLI IQON DATA Capacitor Box ADOYun CTTI ss Figure 10 Standard Wiring for HP Controllers 15 V 4 4 Kelly KHB HP High Power Brushless Motor Controller User s Manual Precharge Resistor 2KO 20W Battery Fuse pru ssa SIG pued mog qg aT ETR TATA ese OLT PSALM i ejap way euondo st s0ystULIAT ymepep iq paremdodap 1514 NFO g 107203002 nd 1242 Suc Xue 210724 g ama 3103 ased 170215 15 0 dyno gra pue qeururza pua ou 02 NT UE Ag 21144 opio se pasn aq uea 13j2umenuajod 45 0 310N Tuo gH3T TaN 2 Diode Main Contactor amy vc 9 0 S 5 omg a ped 5 0 TOON OCT TH gt Yun TT Wak Standard Wiring for KHB Controllers 12V or 24V battery supply is required Figure 11 16 Kelly KHB HP High Power Brushless Motor Controller User s Manual V 4 4 3 2 4 Communication Port A RS232 port is provided to communicate with host computer for calibration and configuration
5. 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 9 This only accurate to 2 upon Overvoltage setting 1 3 H 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 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 seconds of start up Hall sensor or phase wiring problem 2 2 Hu Internal voltage fault 1 Measure that 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 pa naa Over temperature controller temperature has exceeded 100 C The controller will be stopped but will restart when temperature falls below 80 C 2 4 aaan JThrottle error at 1 Throttle signal is higher than the preset dead po
6. 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 22 Kelly KHB HP High Power Brushless Motor Controller User s Manual Contact Us Kelly Controls LLC Home Page http www KellyController com E mail Support KellyController com Phone 01 224 637 5092 V 4 4 23
7. two plugs J1 J2 in back panel are provided for connecting to the battery motor and control signals shown as Figure 5 6 and 9 Figure 5 Front panel of KHB motor controller battery positive B battery negative A U Output A U phase B V Output B V phase C W Output C W phase 11 Kelly KHB HP High Power Brushless Motor Controller User s Manual V 4 4 Kelly Controls LLC Figure 6 Back panel of KHB motor controller 3 2 2 Front Panel and back panel of HP Motor Controller Seven metal bars in front panel and two plugs J1 J2 in back panel are provided for connecting to the battery motor and control signals shown as Figure 7 8 and 9 Figure 7 Front panel of HP motor controller battery positive B battery negative AIU Output A U phase B V Output B V phase C W Output C W phase 12 Kelly KHB HP High Power Brushless Motor Controller User s Manual V 4 4 SOT JO O O 74 Kelly Controls LLC T 8 9 10 11 12 13 14 Figure 8 Back panel of HP motor controller Figure 9 The connecting diagram of J1 and J2 J1 Pin Definition 1 PWR Controller power supply output 2 Current meter lt 200 3 Main contactor driver 2A 4 Alarm To drive reverse beeper lt 200 5 RTN Signal return 6 Green LED Running indication RTN Signal return Reserved Boost Switch only available on the controller with 32 bit micro CAN bus high CAN bus low 12
8. It will stop driving if the battery voltage is too high and it will 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 100 C 6 Enhanced regen brake function A novel ABS technique provides powerful and smooth regen 7 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 8 Pulsed reverse alarm output 9 3 switch inputs which are activated by connection to Ground Default to throttle switch brake switch and reversing switch 10 3 analog 0 5V inputs that default to throttle input brake input and motor temperature input 11 Provision of a 5 volt output to supply various kinds of sensors including Hall effect type 12 Main contactor driver Cutting off the power if any fault is detected 13 Current meter to display both drive and regen current Save shunt 14 3 hall position sensor inputs Open collector pull up provided 15 Maximum reverse speed is configurable to half of max forward speed 16 Configu
9. Kelly KHB HP High Power Brushless Motor Controller User s Manual V 4 4 Kelly High Power Brushless Motor Controller User s Manual Devices Supported KHB72601 KHB72701 KHB72101 KHB12151 KHB12201 KHB12251 KHB12301 KHB12401 KHB12601 KHB12801 KHB14201 KHB14301 KHB14401 KHB14601 HP12101 Rev 4 4 Mar 2014 Kelly KHB HP High Power Brushless Motor Controller User s Manual V 4 4 Contents Chapter 1 Wire quada tu ee 2 UNES iP E 2 Chapter 2 Features and dei tese es 9 2 1 General 3 22 Oe eRe a ee E 4 2 9 DIS CIC AMOI 5 2 4 Naming Regulations seen 5 Chapter 3 Wiprhecandilnsbella 6 3 1 Mounting the Controller eese 6 Z2 COMNECHONS HD 11 3 2 1 Front Panel and back panel of KHB Motor Controller 11 3 2 2 Front Panel and back panel of HP Motor Controller 12 3 2 3 Wiring of KHB HP Motor 15 3 2 4 Communication POLL re it teh rg eg oet oberen 17 3 3 Mounting the Capacitor for HP Motor Controller 17 e Mo s 18 3 4 1 Front Panel and back panel of Capacitor 18 3 5 Installation Check tete 19 Chapter 20 4A Cleaning
10. V brake RTN Signal return or power supply return Red LED Fault code J2 Pin Definition 1 2 3 4 5 6 PWR Controller power supply input RTN Signal return or power supply return RTN Signal return Motor temperature input Throttle analog input 0 5V Brake analog input 0 5V 13 Kelly KHB HP High Power Brushless Motor Controller User s Manual V 4 4 7 5V 5V supply output 40mA 8 Micro SW Throttle switch input 9 Reversing 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 and GND pins are internally connected but isolated from B 2 Two PWR pins J1 1 and J2 1 are internally connected It s recommended to use J1 1 to supply peripherals like alarm and contactor Twist peripheral wires with PWR is the preferred for EMC 3 Kelly Ammeter positive connect to 5V power supply of controller negative to J1 2 4 Switch to ground is active Open switch is inactive 14 V 4 4 Kelly KHB HP High Power Brushless Motor Controller User s Manual 3 2 3 Wiring of KHB HP Motor Controller Precharge Resistor 1 20W Main Contactor ki 200V 3A Diode yams Aay Panpa ssammaLiq pued IT aq TIT JETRI JIO TATA see O TTSALM 02 way enondo st Aq paremdodap 1514 NFO 9 Year 107263002 pnd
11. emote fault code LED driver 26 Current meter output 27 Standard PC Laptop computer is used to do programming No special tools needed 28 User program provided Easy to use No cost to customers Kelly KHB HP High Power Brushless Motor Controller User s Manual V 4 4 2 3 Specifications Frequency of Operation 16 6kHz Standby Battery Current depending on the model usually less than 2mA 5 Sensor Supply Current 40mA Controller supply voltage range PWR 8 to 30V 24V preferred Controller input power PWR less than 10W Configurable battery voltage range Max operating range 18V to 136V for controller rated equal 120V 18V to 180V for controller rated equal 144V 7 Standard Throttle Input 0 5 Volts 3 wire resistive pot 1 4 Volts hall active throttle 8 Analog Brake and Throttle Input 0 5 Volts Producing 0 5V signal with 3 wire pot 9 Reverse Alarm Main Contactor Coil Driver Meter 1 2 3 4 5 6 10 Full Power Operating Temperature Range O0 Cto 50 C controller case temperature 11 Operating Temperature Range 30 to 90 100 shutdown controller case temperature 12 Motor Current Limit 1 minute 150A 1000A depending on the model 13 Motor Current Limit continuous 75A 500A depending on the model 14 Max Battery Current Configurable 2 4 Naming Regulations The naming regulations of Kelly KHB HP BLDC motor con
12. h a host computer through either an RS232 or USB port e Disconnect motor wiring from controller e 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 a straight through RS232 cable or Kelly USB To RS232 Converter to connect to a host computer Provide 10V 30V either J2 pin1 or J1 pin1 to PWR Wire power supply return to any RTN pin isolated from B 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 older 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 20 Kelly KHB HP High Power Brushless Motor Controller User s Manual V 4 4 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 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
13. harge resistors across their contacts Lack of even one of these precharge resistors may severely damage the controller at switch on 3 5 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 Use well insulated tools e sure the wire is connected correctly e Turn on the PWR switch the Red flashes once and the Green is off After the start up delay normally the Red will stay off and the Green will turn on If there is error the Red LED will flashes for fault codes If the S N less 11xxxxxx Turn on the PWR switch the Red flashes once and the Green is on Normally the Red will stay off If there is error the Red LED will flashes for fault codes 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 a
14. nd drive it in a clear area It should have smooth acceleration and good power 19 Kelly KHB HP High Power Brushless Motor Controller User s Manual V 4 4 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 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 and B terminals e 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 e 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 wit
15. ng on voltage source 12V and 5V 7 Current sense on all 3 motor phases 8 Current control loop 9 Hardware over current protection 10 Hardware over voltage protection 11 Support torque mode speed mode and balanced mode operation 12 Configurable limit for motor current and battery current 13 Low EMC 14 LED fault code 15 Battery protection current cutback warning and shutdown at configurable high and low battery voltage 16 Rugged aluminum housing for maximum heat dissipation and harsh environment Support fan or water cooling 17 Rugged high current terminals and rugged aviation connectors for small signal 18 Thermal protection current cut back warning and shutdown at high temperature 19 Configurable 60 degree or 120 degree hall position sensors 20 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 mechanical RPM motor pole pairs 21 Support three modes of regenerative braking brake switch regen release throttle regen 0 5K or 0 5V analog signal variable regen for KHB and HP controllers 22 Configurable high pedal protection the controller will not work if high throttle is detected at power on 23 Current multiplication Take less current from battery output more current to motor 24 Easy installation 2 or 3 wire pot or hall sensor throttle can work with KHB and HIP controllers 25 R
16. rable 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 17 Configurable boost switch Enables the maximum output power achievable if the switch is turned on 18 Configurable economy switch Limits the maximum current to half if the switch is turned on 19 Maximum reverse power is configurable to half power 20 Configurable 12V brake signal input in lieu of motor temperature sensor 21 Optional joystick throttle A bi symmetrical 0 5 signal for both forwarding and reversing 22 Configurable motor over temperature detection and protection with the recommended thermistor KTY84 130 23 Optional CAN bus 24 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 Kelly KHB HP High Power Brushless Motor Controller User s Manual V 4 4 Controller may stop regen without warning to protect itself or the battery it won t protect you 2 2 Features 1 2 Opto isolated technology achieve stability Intelligence with powerful microprocessor 3 Synchronous rectification ultra low drop and fast PWM to achieve very high efficiency 4 Electronic reversing 5 Voltage monitoring on 3 motor phases bus and power supply 6 Voltage monitori
17. trollers KHB12601 The eighth letter represents regeneration 0 non regeneration 1 with regeneration The sixth and seventh letters the max current 10 The fourth and fifth letters nominal voltage 10 The first three letters represent Kelly s high power brushless motor controller Kelly KHB HP High Power Brushless Motor Controller User s Manual V 4 4 HP12101 The seventh letter represents regeneration 0 non regeneration 1 with regeneration The fifth and sixth letters the max current 100 The third and fourth letters nominal voltage 10 The first two letters represent Kelly s high power brushless motor controller Chapter 3 Wiring and Installation 3 1 Mounting the Controller The controller can be oriented in any position which should be as clean and dry as possible and 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 six 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 Kelly KHB HP High Power Brushless Motor Controller User s Manual V 4 4 The case outline and mounting holes dimensions of KHB Controllers 218 56 5 105 56 5
18. wer up zone at Power On Fault clears when throttle is 21 V 4 4 Kelly KHB HP High Power Brushless Motor Controller User s Manual released 2 Setthrottle model as Hall Active throttle in GUI if you use that throttle model 3 1 Frequent reset May be caused by over voltage bad motor intermittent earthing problem bad wiring etc 3 2 pan Internal reset May be caused by some transient fault condition like a temporary over current momentarily high or low battery voltage This can happen during normal operation 3 3 oan ann Hall throttle is open When the throttle is repaired a restart will clear the or short circuit fault 3 4 nuum 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 nuum n 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 nu 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 ooo Motor 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
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