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Kelly Ebike Brushless DC Motor Controller User’s Manual

V 3.4

Kelly KEB Brushless Motor

Controller User’s Manual

Devices Supported:

KEB48200X KEB48201X

KEB48300X KEB48301X

KEB48400X KEB48401X

KEB48600

KEB48601

KEB72300X KEB72301X

KEB72450X KEB72451X

KEB72600X KEB72601X

KEB72800X KEB72801X

KEB72100

KEB72101

KEB72120E KEB72121E

KEB84600X KEB84601X

KEB84800X KEB84801X

KEB84120E KEB84121E

Rev.3.4

Dec. 2016

Summary of Contents for KEB48200X

Page 1: ...ser s Manual Devices Supported KEB48200X KEB48201X KEB48300X KEB48301X KEB48400X KEB48401X KEB48600 KEB48601 KEB72300X KEB72301X KEB72450X KEB72451X KEB72600X KEB72601X KEB72800X KEB72801X KEB72100 KEB72101 KEB72120E KEB72121E KEB84600X KEB84601X KEB84800X KEB84801X KEB84120E KEB84121E Rev 3 4 Dec 2016 ...

Page 2: ...s 3 2 2 Features 4 2 3 Specifications 5 2 4 Models 5 Chapter 3 Wiring and Installation 6 3 1 Mounting the Controller 6 3 2 Connections 8 3 2 1 Front Panel of KEB Motor Controller 8 3 2 2 Standard Wiring of KEB Motor Controller 10 3 2 3 Communication Port 11 3 3 Installation Check List 11 Chapter 4 Maintenance 12 4 1 Cleaning 12 4 2 Configuration 12 Table 1 LED CODES 13 Contact Us 15 ...

Page 3: ...y s programmable KEB motor controllers provide efficient smooth and quiet controls for electric bicycles electric motorcycles scooters etc It outputs high taking off current and strictly limit battery current It can work with relative small battery but provide good acceleration and hill climbing It uses high power MOSFET s and PWM to achieve efficiencies of up to 99 In most cases Powerful micropro...

Page 4: ...o 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 11 3 analog inputs 0 5V inputs that default to throttle input brake input and motor temperature input 12 Configurable boost switch Enables the maximum output power achievable if the switch is turned on 13 Configurab...

Page 5: ...dware over voltage protection Support torque mode speed mode and balanced mode operation Configurable limit for motor current and battery current Battery current limiting available doesn t affect taking off performance More startup current can get more startup speed Low EMC LED fault code Battery protection current cutback warning and shutdown at configurable high and low battery voltage Rugged al...

Page 6: ...ge PWR 18V to 90V Supply Current PWR 150mA Configurable battery voltage range B Max operating range 18V to 1 25 Nominal Standard Throttle Input 0 5 Volts 3 wire resistive pot 1 4 Volts hall active throttle Analog Brake and Throttle Input 0 5 Volts Producing 0 5V signal with 3 wire pot Full Power Operating Temperature Range 0 to 50 controller case temperature Operating Temperature Range 30 to 90 10...

Page 7: ...s 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 1...

Page 8: ...Kelly Ebike Brushless DC Motor Controller User s Manual V 3 4 Page 7 Height 62 millimeters Figure 2 KEB E mounting holes dimensions dimensions in millimeters ...

Page 9: ... Front panel of KEB motor controller B battery positive B battery negative A Output U 1 A phase B Output V 2 B phase C Output W 3 C phase Figure 4 The connecting diagram of J2 J2 Pin Definition 1 PWR Controller power supply 2 RTN Signal return or power supply ground 3 RTN Signal return 4 12V high level brake and motor temperature input 5 Throttle analog input 0 5V 6 Brake analog input 0 5V 7 5V 5V...

Page 10: ... until you are certain the controller wiring is correct and has been double checked Wiring faults will damage the controller Ensure that the B wiring is securely and properly connected before applying power The preferred connection of the system contactor or circuit breaker is in series with the B line All contactors or circuit breakers in the B line must have precharge resistors across their cont...

Page 11: ...lly Ebike Brushless DC Motor Controller User s Manual V 3 4 Page 10 3 2 2 Standard Wiring of KEB Motor Controller Figure 5 KEB controller standard wiring Battery voltage can be used for controller supply ...

Page 12: ...ke sure the PWR switch and the brake is off Use well insulated 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 controller ground The fault code will be detected automatically at restart With the brake switch open select a directio...

Page 13: ...ake 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 4 2 Configuration You can configure the controller with a host computer through either an RS232 or USB port Disconnect motor wiring from controller Do not connect B throttle and so on The control...

Page 14: ...lts 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 controller cools down 2 Clean or improve heatsink or fan 2 1 Motor did not start Motor did not reach 25 electrical RPM within 2 seconds of start up Hall sensor or phase wiring problem 2 2 Intern...

Page 15: ...ss 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 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 o...

Page 16: ...Kelly Ebike Brushless DC Motor Controller User s Manual V 3 4 Page 15 Contact Us Kelly Controls Home Page http www KellyController com E mail Support KellyController com Phone 001 224 637 5092 ...

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