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 16

Table

Table

Table

Table 2

2

2

2:::: KBL

KBL

KBL

KBL Controller

Controller

Controller

Controller CAN

CAN

CAN

CAN Commands

Commands

Commands

Commands List

List

List

List

V

V

V

Version

ersion

ersion

ersion 1.1

1.1

1.1

1.1

You

You

You

You should

should

should

should specify

specify

specify

specify when

when

when

when sending:

sending:

sending:

sending:

ID:

ID:

ID:

ID:

Our default ID is 0x6B, so only the data frame with ID 107 can be received by our controller.

However, it can be set by configuration program.

Frame

Frame

Frame

Frame type:

type:

type:

type:

data frame

Frame

Frame

Frame

Frame format:

format:

format:

format:

standard 11 bits ID

Length:

Length:

Length:

Length:

the number of data field bytes

Data

Data

Data

Data field:

field:

field:

field:

data[0] is the command which indicates the operation.

Controller

Controller

Controller

Controller response

response

response

response::::

ID:

ID:

ID:

ID:

The controller sends data frames with ID 115, 0x73. It also can be set by configuration program.

Frame

Frame

Frame

Frame type:

type:

type:

type:

data frame

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[7] Controller’s model in ASCII format, 8 bytes.
Description: Getting controller’s model no. E.g. 0x4B,0x42,0x4C is 'K' , 'B', 'L', 0x30 is '0' .

INFO_MODULE_NAME constant is defined as 64.

Command

CCP

CCP

CCP

CCP_FLASH_READ

_FLASH_READ

_FLASH_READ

_FLASH_READ

Length

3

data[0]

0xF2

data[1]

INFO_SOFTWARE_VER

data[2]

2

Controller response
Length

2

data[0]~data[1] software version in BCD alike format, two bytes.
Description: Getting controller’s software version,

it also define as the controller’s version, BCD

alike format storage. E.g. 0x0A,0x01 should be parsed to ASCII characters ‘0’ ‘A’ ‘0’ ‘1’ as the software
version. INFO_SOFTWARE_VER constant is defined as 83.

Command

CCP

CCP

CCP

CCP_FLASH_READ

_FLASH_READ

_FLASH_READ

_FLASH_READ

Length

3

data[0]

0xF2

data[1]

CAL_TPS_DEAD_ZONE_LOW

data[2]

1

Controller response
Length

1

data[0]

TPS_Dead_Zone_Low

Desccription: Getting controller’s Throttle low-end dead zone. CAL_TPS_DEAD_ZONE_LOW

constant is defined as 4. The maximum value of Throttle is 200. If the value of Throttle Low-end Dead
Zone is 40, indicating 20% low-end dead zone. (40/200 is 20%.)

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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