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Kelly KBS-E Brushless Motor Controller User’s Manual

V 1.2

Kelly KBS-E Brushless Motor

Controller User’s Manual

Devices Supported:

Rev.1.2

Dec.2016

KBS48151E

KBS72151E

KBS48181E

KBS72181E

KBS48221E

KBS72221E

Summary of Contents for KBS48151E

Page 1: ...lly KBS E Brushless Motor Controller User s Manual V 1 2 Kelly KBS E Brushless Motor Controller User s Manual Devices Supported Rev 1 2 Dec 2016 KBS48151E KBS72151E KBS48181E KBS72181E KBS48221E KBS72221E ...

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 10 3 3 Installation Check List 16 Chapter 4 Programmable Parameters 17 4 1 Step 1 17 4 2 Step 2 18 4 3 Step 3 19 4 4 Step 4 20 4 5 Step 5 21 Chapter 5 Maintenance 22 5 1 Cleaning 22 5 2 Configuration 22 Table 1 LED CODES 23 Contact Us 25 ...

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: ... 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 Elec...

Page 6: ...inal 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 10 seconds boost 1...

Page 7: ... 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 four screws Applying silicon grease or some other thermal conductive ...

Page 8: ...Kelly KBS E Brushless Motor Controller User s Manual V 1 2 7 Height 41 millimeters Figure 1 KBSXX151E mounting holes dimensions dimensions in millimeters ...

Page 9: ...Kelly KBS E Brushless Motor Controller User s Manual V 1 2 8 Height 51 5 millimeters Figure 2 KBSXX181E mounting holes dimensions dimensions in millimeters ...

Page 10: ...Kelly KBS E Brushless Motor Controller User s Manual V 1 2 9 Height 58 5 millimeters Figure 3 KBSXX221E mounting holes dimensions dimensions in millimeters ...

Page 11: ...onnections 3 2 1 Pin definition of KBS E Controller Figure 4 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 12: ...h 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 d...

Page 13: ...ushless Motor Controller User s Manual V 1 2 12 3 2 2 Wiring of KBS E Controller 3 2 2 1 Standard wiring of KBS E controller Figure 5 KBS E controller standard wiring Battery voltage can be used for controller supply ...

Page 14: ...Kelly KBS E Brushless Motor Controller User s Manual V 1 2 13 Figure 6 KBS E F N R control wiring diagram ...

Page 15: ...nal source Figure 9 Wiring of brake switch 12V 12V is provided by KBS X controller on pin11 Figure 10 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 16: ...nual V 1 2 15 3 2 3 Communication Port A RS232 port is provided to communicate with host computer for calibration and configuration Figure 11 RS232 Interface on KBS controller Figure 12 SM 4P connector for communication interface on KBS E controller ...

Page 17: ...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 18: ...ot switch will be activated The controller 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 E...

Page 19: ... longer delay time Suggestion Set according 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 resp...

Page 20: ...etect 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 100 2 Half Spee...

Page 21: ...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 energy and charge back to battery Suggesti...

Page 22: ...al 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 function Controller Stop Output Temperatu...

Page 23: ...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 24: ...battery too high 3 The controller is damaged Contact Kelly about a warranty repair Red LED Codes LED Code Explanation Solution 1 1 Automatic error identification 1 Wrong wiring of motor phase line or hall Please suspend the motor when enable Auto Identify function 1 2 Over voltage error 2 Battery voltage is too high for the controller Check battery volts and configuration 3 Regeneration over volta...

Page 25: ... low battery voltage This can happen during normal operation 3 3 Hall throttle is open or 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 vo...

Page 26: ...Kelly KBS E Brushless Motor Controller User s Manual V 1 2 25 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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