Kelly KBS-X Series User Manual Download

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Kelly KBS-X Brushless Motor Controller User

’s Manual

V 4.2

Kelly KBS-X Brushless Motor

Controller User’s Manual

Devices Supported:

KBS24051X

KBS24101X

KBS24121X

KBS36051X

KBS36101X

KBS48051X

KBS48101X

KBS48121X

KBS72051X

KBS72101X

KBS72121X

Rev.4.2

July, 2022

Summary of Contents for KBS-X Series

Page 1: ...Controller User s Manual V 4 2 Kelly KBS X Brushless Motor Controller User s Manual Devices Supported KBS24051X KBS24101X KBS24121X KBS36051X KBS36101X KBS48051X KBS48101X KBS48121X KBS72051X KBS72101X KBS72121X Rev 4 2 July 2022 ...

Page 2: ...2 2 Features 4 2 3 Specifications 5 2 4 Name Regulation 5 Chapter 3 Wiring and Installation 6 3 1 Mounting the Controller 7 3 2 Connections 8 3 3 Installation Check List 14 Chapter 4 Programmable Parameters 15 4 1 Step 1 15 4 2 Step 2 16 4 3 Step 3 17 4 4 Step 4 18 4 5 Step 5 19 Chapter 5 Maintenance 20 5 1 Cleaning 20 5 2 Configuration 20 Table 1 LED CODES 21 Contact Us 23 ...

Page 3: ...contact the support center of Kelly Controls Kelly s programmable motor controllers provide efficient smooth and quiet controls for electric motorcycles golf carts and go carts 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 controll...

Page 4: ...uding Hall effect type 10 3 switch inputs which are activated by connection to Ground Default to throttle switch brake switch and reversing switch 11 3 analog 0 5V inputs that default to throttle input brake input and motor temperature input 12 Pulsed reverse alarm output 13 Main contactor driver Cutting off the power if any fault is detected 14 Current meter to display both drive and regen curren...

Page 5: ... Rugged aluminum housing for maximum heat dissipation and harsh environment 16 Rugged high current terminals and rugged aviation connectors for small signal 17 Thermal protection current cut back warning and shutdown on high temperature 18 Configurable 60 degree or 120 degree hall position sensors 19 Support motors with any number of poles 20 Up to 40 000 electric RPM standard Electric RPM mechani...

Page 6: ...minal Voltage Standard Throttle Input 0 5 Volts 3 wire resistive pot 1 4 Volts hall active throttle Analog Brake and Throttle Input 0 5 Volts Can use 3 wire pot to produce 0 5V signal Reverse Alarm Meter 200mA Main Contactor Coil Driver 2A Full Power Operating Temperature Range 0 to 70 MOSFET temperature Operating Temperature Range 40 to 100 MOSFET temperature Motor Current Limit 30 seconds boost ...

Page 7: ...S24121X 120 55 12 24 30 KBS36051X 50 25 24 36 45 KBS36101X 100 45 24 36 45 KBS48051X 50 25 24 48 60 KBS48101X 100 40 24 48 60 KBS48121X 120 55 24 48 60 KBS72051X 50 25 24 72 86 KBS72101X 100 40 24 72 86 KBS72121X 120 55 24 72 86 1 24V model range of the max operating voltage is 8 30V 2 36V model range of the max operating voltage is 18 45V 3 48V model range of the max operating voltage is 18 60V 4...

Page 8: ...nd contaminants To ensure full rated output power the controller should be fastened to a clean flat metal surface with four 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 The case outline and mounting holes dimensions are sho...

Page 9: ...nnections 3 2 1 Pin definition of KBS X Controller Figure 2 waterproof connector DJ7061Y 2 3 21 Pin Definition 21 RTN Signal return Black 5 5V 5V supply output 40mA Purple 18 Hall A Hall phase A Yellow 17 Hall B Hall phase B Dark Green 16 Hall C Hall phase C Dark Blue ...

Page 10: ... input Brown 4 5V 5V supply output 40mA Purple 2 BRK_AN Brake analog input 0 5V Dark Gray 22 Reservation Green Notes 1 All RTN pins are internally connected 2 Kelly Ammeter positive connect to 5V power supply of controller negative to Dark Blue wire 3 Switch to ground is active Open switch is inactive Caution Do not apply power until you are certain the controller wiring is correct and has been do...

Page 11: ...ushless Motor Controller User s Manual V 4 2 10 3 2 2 Wiring of KBS X Controller 3 2 2 1 Standard wiring of KBS Xcontroller Figure 3 KBS X controller standard wiring Battery voltage can be used for controller supply ...

Page 12: ...Kelly KBS X Brushless Motor Controller User s Manual V 4 2 11 Figure 4 KBS X F N R control wiring diagram ...

Page 13: ...rnal source Figure 7 Wiring of brake switch 12V 12V is provided by KBS X controller on pin11 Figure 8 Wiring of motor temperature sensor pin1 Brk2 can be used as motor temperature sensor port Note The motor temperature sensor item must be enabled in the user program for three kinds of wiring diagrams By default Kelly controller supports KTY84 130 and KTY83 122 thermistors Either of them can be cho...

Page 14: ...anual V 4 2 13 3 2 3 Communication Port A RS232 port is provided to communicate with host computer for calibration and configuration Figure 9 RS232 Interface on KBS controller Figure 10 SM 4P connector for communication interface on KBS X controller ...

Page 15: ...he 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...

Page 16: ...oller will not accept the throttle signal if the foot switch is turned off Please see figure 4 1 Suggestion Set according to the practical situation factory default is Disable Configuration Pin Status Running Status Forward Switch Foot Switch FWD_SW 12 REV_SW 14 Foot 15 Enable Disable OFF OFF x Neutral OFF ON x Reverse ON OFF x Forward ON ON x Neutral Disable Enable x OFF OFF Can t operate x ON OF...

Page 17: ...ording to the practical situation factory default is 0 5s 2 Hall Sensor Type Value range 60 degree and 120 degree Functional description Set according to your motor hall sensor type Suggestion Set according to the practical situation 3 Control Mode Value range Torque Balanced Speed Functional description Set controller output mode Torque mode brings faster response of the load and good acceleratio...

Page 18: ...ntroller will detect the current pedal status when release the brake If throttle got effective output the controller will report fault and not operate Suggestion Set according to the practical situation factory default is Enable 4 3 Step 3 1 Motor Top Speed Value range 30 100 Functional description Limit top speed of the motor Suggestion Set according to the practical situation factory default is ...

Page 19: ... 7 Motor Top Speed In Reverse Value range 20 100 Functional description Limit max reverse speed of the motor Suggestion This function is available for firmware version 0104 or later Set according to the practical situation factory default is 100 4 4 Step 4 1 Regeneration Value range Enable and Disable Functional description If enabled the controller can do regen braking It will recover mechanical ...

Page 20: ...nt Suggestion Set according to the practical situation factory default is 10 8 Brake Sensor Ending Point Value range 60 100 Functional description Set brake sensor effective ending point Suggestion Set according to the practical situation factory default is 90 4 5 Step 5 1 Motor Temperature Sensor Value range Enable and Disable Functional description If use motor temperature sensor and enable this...

Page 21: ...ontactor coil resistor or a horn across the controller s B and B terminals Remove any dirt or corrosion from the bus bar area The controller should be wiped with a moist rag Make sure that the controller is dry before reconnecting the battery Make sure the connections to the bus bars if fitted are tight To avoid physically stressing the bus bars use two well insulated wrenches 5 2 Configuration Yo...

Page 22: ...he controller is damaged Contact Kelly about a warranty repair Red LED Codes LED Code Explanation Solution 1 2 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 3 This only accurate to 2 upon Overvoltage setting 1 3 Low voltage error 1 The controller will clear after 5...

Page 23: ... short circuit When the throttle is repaired a restart will clear the fault 3 4 Non zero throttle on direction change Controller won t allow a direction change unless the throttle or speed is at zero Fault clears when throttle 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 se...

Page 24: ...Kelly KBS X Brushless Motor Controller User s Manual V 4 2 23 Contact Us Kelly Controls Home Page http www KellyController com E mail sales kelly controls com Phone 01 224 637 5092 ...

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