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Kelly KBS Brushless Motor Controller User’s Manual

V 4.1

9

Figure 3: KBS-L

controller standard wiring

(Battery voltage can be used for controller supply)

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Summary of Contents for KBS24051L

Page 1: ...Controller User s Manual V 4 1 Kelly KBS L Brushless Motor Controller User s Manual Devices Supported KBS24051L KBS24101L KBS24121L KBS36051L KBS36101L KBS48051L KBS48101L KBS48121L KBS72051L KBS72101L KBS72121L Rev 4 1 Jan 2014 ...

Page 2: ... 2 Features 4 2 3 Specifications 5 2 4 Name Regulation 5 Chapter 3 Wiring and Installation 6 3 1 Mounting the Controller 6 3 2 Connections 7 3 3 Installation Check List 10 Chapter 4 Programmable Parameters 11 4 1 Step 1 11 4 2 Step 2 13 4 3 Step 3 14 4 4 Step 4 15 4 5 Step 5 16 Chapter 5 Maintenance 16 5 1 Cleaning 16 5 2 Configuration 17 Table 1 LED CODES 17 Contact Us 20 ...

Page 3: ...ontact 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 controlle...

Page 4: ...ding 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 current...

Page 5: ...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 Optional high speed 70 000 ERPM Elect...

Page 6: ...tandard 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 Main Contactor Coil Driver Meter 200mA Full Power Operating Temperature Range 0 to 50 controller case temperature Operating Temperature Range 30 to 90 100 shutdown controller case temperature Motor Current Limit 10 se...

Page 7: ...nts 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 shown in Figure...

Page 8: ...onnections 3 2 1 Pin definition of KBS L KBS X Controller Figure 2 waterproof connector Hall Connector Pin Definition 21 RTN Signal return Black 5 5V 5V supply output 40mA Orange 18 Hall A Hall phase A Yellow 17 Hall B Hall phase B Green 16 Hall C Hall phase C Blue ...

Page 9: ...ply output 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 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 double checked Wiring fa...

Page 10: ...Kelly KBS Brushless Motor Controller User s Manual V 4 1 9 Figure 3 KBS L controller standard wiring Battery voltage can be used for controller supply ...

Page 11: ...ort is provided to communicate with host computer for calibration and configuration Figure 6 RS232 Interface on KBS controller 3 3 Installation Check List Before operating the vehicle complete the following checkout procedure 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 ...

Page 12: ...un 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 Chapter 4 Programmable Parameters KBS Configuration program allow users to set parameters according to the vehicle actual working environment so as to be at its be...

Page 13: ... Functional description Set throttle sensor type Suggestion Set according to the practical situation factory default is 3 wire resistive pot 4 Throttle Effective Starting Point Value range 10 40 Functional description Set throttle effective starting point Suggestion Set according to the practical situation factory default is 10 5 Throttle Effective Ending Point Value range 60 100 Functional descri...

Page 14: ... smooth operation and wide speed adjusting range Suggestion Set according to the practical situation factory default is Torque mode 4 Under Voltage Value range Please see Figure 4 2 Functional description Controller will not operate when battery voltage is lower than the value so as to protect battery Suggestion Set according to the practical situation 5 Over Voltage Value range Please see Figure ...

Page 15: ...on factory default is 100 2 Half Speed In Reverse Value range Enable and Disable Functional description If enabled the max reverse speed of the motor will be limited to half of the max forward speed Suggestion This function is available for firmware version 0103 or less Set according to the practical situation factory default is Disable 3 Boost Function Value range Enable and Disable Functional de...

Page 16: ...rn off throttle and turn on brake switch will start regen Suggestion Set according to the practical situation 3 Releasing Throttle Regen Mode and Max Allowed Regen Current Value range 0 20 Functional description Set the max allowed regen current in releasing throttle regen mode Suggestion Set according to the practical situation factory default is 0 4 Max Allowed Regen Current In Brake Switch Rege...

Page 17: ...cording to the practical situation 3 Controller Resume Output Temperature Value range 60 170 Functional description Controller will resume output if motor temperature reaches the set value Suggestion Set according to the practical situation Note Thermistor is optional Default to KTY84 130 Chapter 5 Maintenance There are no user serviceable parts inside the controllers Do not attempt to open the co...

Page 18: ... PWR for a 24V controller provide 8V Wire power supply return supply negative to any RTN pin KBS L user program can not work with KBS X controller vice versa Only KBS X requires Kelly RS232 Converter to support the communication 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 Configu...

Page 19: ...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 Over temperature The controller temperature has exceeded 100 The controller will be stopped but will restart when temperature falls below 80 2 4 Throttle error at power up Throttle signal is higher than th...

Page 20: ...lso be caused by incorrect hall angle configuration 60 degree or 120 degree 4 3 Motor over temperature Motor temperature has exceeded the configured maximum The controller will shut down until the motor temperature cools down The Red LED flashes once at power on 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 be...

Page 21: ...Kelly KBS Brushless Motor Controller User s Manual V 4 1 20 Contact Us Kelly Controls Home Page http www KellyController com E mail Support KellyController com Phone 01 224 637 5092 ...

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