background image

Kelly

Kelly

Kelly

Kelly KBL

KBL

KBL

KBL Brushless

Brushless

Brushless

Brushless Motor

Motor

Motor

Motor Controller

Controller

Controller

Controller User

User

User

User’’’’s

s

s

s Manual

Manual

Manual

Manual

V

V

V

V 3.3

3.3

3.3

3.3

Page 12

3.2.

3.2.

3.2.

3.2.3

3

3

3 Communication

Communication

Communication

Communication Port

Port

Port

Port

A RS232 port is provided to communicate with host computer for calibration and configuration.

Figure

Figure

Figure

Figure 7:

7:

7:

7:

standard RS232 Interface

3.3

3.3

3.3

3.3 Installation

Installation

Installation

Installation Check

Check

Check

Check List

List

List

List

Before operating the vehicle, complete the following checkout procedures. Use LED code

as a reference as listed in Table 1.

Caution:

Caution:

Caution:

Caution:

Put

Put

Put

Put the

the

the

the vehicle

vehicle

vehicle

vehicle up

up

up

up on

on

on

on blocks

blocks

blocks

blocks to

to

to

to get

get

get

get the

the

the

the drive

drive

drive

drive wheels

wheels

wheels

wheels off

off

off

off the

the

the

the ground

ground

ground

ground before

before

before

before beginning

beginning

beginning

beginning these

these

these

these

tests.

tests.

tests.

tests.

Do

Do

Do

Do not

not

not

not allow

allow

allow

allow anyone

anyone

anyone

anyone to

to

to

to stand

stand

stand

stand directly

directly

directly

directly in

in

in

in front

front

front

front of

of

of

of or

or

or

or behind

behind

behind

behind the

the

the

the vehicle

vehicle

vehicle

vehicle during

during

during

during the

the

the

the checkout.

checkout.

checkout.

checkout.

Make

Make

Make

Make sure

sure

sure

sure the

the

the

the PWR

PWR

PWR

PWR switch

switch

switch

switch and

and

and

and the

the

the

the brake

brake

brake

brake is

is

is

is off

off

off

off

Use

Use

Use

Use well-insulated

well-insulated

well-insulated

well-insulated tools.

tools.

tools.

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

return.

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 power.

Summary of Contents for KBL09151

Page 1: ...1 KBL09151 KBL24151 KBL24151 KBL24151 KBL24151 KBL36151 KBL36151 KBL36151 KBL36151 KBL09201 KBL09201 KBL09201 KBL09201 KBL24201 KBL24201 KBL24201 KBL24201 KBL36201 KBL36201 KBL36201 KBL36201 KBL09251 KBL09251 KBL09251 KBL09251 KBL24301 KBL24301 KBL24301 KBL24301 KBL36301 KBL36301 KBL36301 KBL36301 KBL09401B KBL09401B KBL09401B KBL09401B KBL48101 KBL48101 KBL48101 KBL48101 KBL72101 KBL72101 KBL7210...

Page 2: ...ontents Chapter 1 Introduction 2 1 1 Overview 2 Chapter 2 Features and Specifications 3 2 1 General functions 3 2 2 Features 4 2 3 Specifications 4 2 4 Naming Regulations 5 Chapter 3 Wiring and Installation 6 3 1 Mounting the Controller 6 3 2 Connections 7 3 3 Installation Check List 12 Chapter 4 Maintenance 13 4 1 Cleaning 13 4 2 Configuration 13 Table 1 LED CODES 14 Green LED Codes 14 Red LED Co...

Page 3: ...ance 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 efficient smooth and quiet controls for golf carts go carts electric motorcycles forklifts hybrid vehicles electric vehicles and electric boats as well as industrial motor speed or torque control I...

Page 4: ...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 Closing to ground is to activate 11 3 analog 0 5V inputs that default to thr...

Page 5: ...nal 17 Thermal protection current cut back warning and shutdown at high temperature 18 Configurable 60 degree or 120 degree hall position sensors 19 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 20 Support three modes of regenerative braking brake switch regen...

Page 6: ...log Brake and Throttle Input 0 5 Volts Producing 0 5V signal with 3 wire pot Reverse Alarm Main Contactor Coil Driver Meter Full Power Operating Temperature Range 0 ﹾ C to 50 ﹾ C controller case temperature Operating Temperature Range 30 ﹾ C to 90 ﹾ C 100 ﹾ C shutdown controller case temperature Motor Current Limit 1 minute 100 500A depending on the model Motor Current Limit continuous 50A 250A de...

Page 7: ...e 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 or six screws Applying silicon grease or some other thermal conductive material to contact surface will enhance thermal perfo...

Page 8: ...g holes dimensions dimensions in millimeters 3 2 3 2 3 2 3 2 Connections Connections Connections Connections 3 2 1 3 2 1 3 2 1 3 2 1 Front Front Front Front Panel Panel Panel Panel of of of of BLDC BLDC BLDC BLDC Motor Motor Motor Motor Controller Controller Controller Controller Five metal bars and two plugs J1 J2 are provided for connecting to the battery motor and control signals in the front o...

Page 9: ...gh high high 11 11 11 11 CAN CAN CAN CAN bus bus bus bus low low low low 12 12 12 12 Reserved Reserved Reserved Reserved 13 13 13 13 RTN RTN RTN RTN Signal Signal Signal Signal r r r return eturn eturn eturn or or or or power power power power supply supply supply supply return return return return 14 14 14 14 Red Red Red Red LED LED LED LED F F F Fault ault ault ault code code code code The The T...

Page 10: ...power power until until until until you you you you are are are are certain certain certain certain the the the the controller controller controller controller wiring wiring wiring wiring is is is is correct correct correct correct and and and and has has has has been been been been double double double double checked checked checked checked W W W Wiring iring iring iring faults faults faults faul...

Page 11: ...2 2 3 2 2 3 2 2 3 2 2 Wiring Wiring Wiring Wiring of of of of BLDC BLDC BLDC BLDC Motor Motor Motor Motor Controller Controller Controller Controller Figure Figure Figure Figure 5 5 5 5 Standard Standard Standard Standard Wiring Wiring Wiring Wiring for for for for Controllers Controllers Controllers Controllers Rated Rated Rated Rated Equal Equal Equal Equal or or or or Lower Lower Lower Lower Th...

Page 12: ...ser User User User s s s s Manual Manual Manual Manual V V V V 3 3 3 3 3 3 3 3 Page 11 Figure Figure Figure Figure 6 6 6 6 BLDC BLDC BLDC BLDC controller controller controller controller preferred preferred preferred preferred wiring wiring wiring wiring 24V 24V 24V 24V supply supply supply supply is is is is preferred preferred preferred preferred ...

Page 13: ... Do Do not not not not allow allow allow allow anyone anyone anyone anyone to to to to stand stand stand stand directly directly directly directly in in in in front front front front of of of of or or or or behind behind behind behind the the the the vehicle vehicle vehicle vehicle during during during during the the the the checkout checkout checkout checkout Make Make Make Make sure sure sure su...

Page 14: ...configuration Use straight through RS232 cable or USB converter provided by Kelly to connect to a host computer Provide 18V to PWR for a 24V controller provide 8V Wire power supply return supply negative to any RTN pin Download the free configuration software from http www kellycontroller com support php http www kellycontroller com support php http www kellycontroller com support php http www kel...

Page 15: ...er 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 recharge if required 1 4 Over temperature warning 1 Controller case temperature is above 90 Current will be limited Reduce controller loading or switch Off until contro...

Page 16: ...ttle is released 4 1 Regen or Start up over voltage Motor drive is disabled if an over voltage is detected at start up or during regen The voltage threshold detection level is set during configuration 4 2 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 Motor over temperature Motor temperature ...

Page 17: ...e Length Length Length Length the number of data field bytes Data Data Data Data field field field field The controller sends a data frame in response Commands Commands Commands Commands definitions definitions definitions definitions Command CCP CCP CCP CCP_FLASH_READ _FLASH_READ _FLASH_READ _FLASH_READ Length 3 data 0 0xF2 data 1 INFO_MODULE_NAME data 2 8 Controller response Length 8 data 0 data...

Page 18: ...20 low end dead zone 20 100 is 20 Command CCP CCP CCP CCP_FLASH_READ _FLASH_READ _FLASH_READ _FLASH_READ Length 3 data 0 0xF2 data 1 CAL_BRAKE_DEAD_ZONE_HIGH data 2 1 Controller response Length 1 data 0 Brake_Dead_Zone_High Desccription Getting controller s Brake high end dead zone CAL_BRAKE_DEAD_ZONE_HIGH constant is defined as 39 The maximum value of Brake is 100 If the value of Brake High end D...

Page 19: ... reading 3 PWM is output duty cycle from 0 to 100 4 data 1 indicates enabling motor rotation or disabling 1 enable 0 disable 5 data 2 is defined as the temperature of motor in Celsius temperature If the temperature sensor is not connected the controller returns 0xFF 6 data 3 data 5 are defined as controller inside temperature in Celsius temperature The value of data 4 and data 5 are inaccurate bel...

Page 20: ...W_REV COM_SW_REV Length 2 data 0 0x44 data 0 COM_READING Controller response Length 1 data 0 Current Reverse switch status Description Getting Reverse swith status 1 active 0 inactive COM_READING constant is defined as 0 NOTICE NOTICE NOTICE NOTICE 1 CAN bus rate should be configured to 1Mbit s 2 If the command is out of above commands Controller response Length 1 data 0 CCP_INVALID_COMMAND Descri...

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