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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....1

1

1

1

Page 15

2,4

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Throttle error at
power up

1. The throttle signal is higher than configured dead

zone at power-on

2. The fault will disappear if restart or release

throttle.

3,1

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Frequent reset

1. The controller will stop driving after detect too

many resets.

2. Mostly because of B- or return wiring. Use

heavier and clean return wires. For dual

controllers, bond B- of both controllers together

with heavy cable or copper strip.

3. Could be over current protection. May set max

current lower.

4.

Restart will clear the error.

5.

Please contact Kelly if it happens repeatedly

3,2

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Internal reset

Reset caused by over current, high battery voltage or

low supply voltage. It is normal if occurs occasionally.

3,4

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Throttle isn’t zero
when try to change
direction

The controller won’t change drive direction if throttle

isn’t zero. Also it won’t change direction at high

speed. The controller will wait throttle and speed

close to zero before change direction.

4,1

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Over voltage at
startup or
regeneration

The controller won’t drive motor if detect overvoltage

at power up. It will cut back regen current or stop

regen at overvoltage. You may set max voltage

threshold with GUI.

4, 2

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Hall sensor signal
error

1. Most likely caused by incorrect hall wiring, to

wrong pin or loose wire.

2. Intermittent or damaged hall sensor

3. Double check hall angle setting, 60 degree or 120

degree

4, 3

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Motor over
temperature

1.The motor temperature higher than configured max

temperature. Controller will shutdown and wait for

motor temperature drops.

2.Can change the temperature setting with

configuration program.

The LED flashes once at power on, then keeps on for normal operation. “1, 2” means

it flashed once, then flashes twice after 1 second. The time between two flashes is 0.5
second. The pause time between one error code and another error code is 2 second.

Содержание KBL12151H

Страница 1: ...2 362 36201 01 01 01 KBL KBL KBL KBL243 243 243 24301 01 01 01 KBL KBL KBL KBL363 363 363 36301 01 01 01 KBL48101 KBL48101 KBL48101 KBL48101 KBL72101 KBL72101 KBL72101 KBL72101 KBL48151 KBL48151 KBL48151 KBL48151 KBL72151 KBL72151 KBL72151 KBL72151 KBL48201 KBL48201 KBL48201 KBL48201 KBL72201 KBL72201 KBL72201 KBL72201 KBL48301 KBL48301 KBL48301 KBL48301 KBL72301 KBL72301 KBL72301 KBL72301 KBL48 K...

Страница 2: ...y KBL Series Brushless Motor Controller User s Manual 0 Contents 1 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 Name Regulation 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 Configurati...

Страница 3: ...aintenance Read the manual carefully and thoroughly before use the controller Should you have any questions please contact the support center of Kelly Controls LLC Kelly s programmable motor controllers provide efficient smooth and quite controls for golf cart go cart electric motorcycle forklift hybrid vehicle electrical vehicle electric boat as well as industry motor speed or torque control It u...

Страница 4: ... to half of max forward speed 8 Configurable and programmable with RS 232 Software upgradeable Windows GUI provided 9 Provide 5V sensor supply 10 3 switch inputs Close to ground to activate Default to throttle switch brake switch and reverse switch 11 3 analog inputs 0 5V Default to throttle input brake input and motor temperature input 12 Reverse alarm output Recirculation diodes provided 13 Main...

Страница 5: ...ctric RPM Electric RPM mechanical RPM motor poles 13 Three modes of regen brake switch regen release throttle regen 0 5V signal regen 14 High pedal protection Disable operation if power up with non zero throttle 15 Current multiplication Take less current from battery output more current to motor 16 Easy installation 3 wire potentiometer will work 2 3 2 3 2 3 2 3 Specifications Specifications Spec...

Страница 6: ... 2 4 2 4 2 4 Name Name Name Name Regulation Regulation Regulation Regulation The name regulation of Kelly BLDC motor controllers The eighth letter represents regeneration 0 non regeneration 1 with regeneration The sixth and seventh letters represent the max current divided by 10 The fourth and fifth letters represent nominal voltage The first three letters represent Kelly s brushless motor control...

Страница 7: ...er Controller Controller Controller The controller can be oriented in any position as clean and dry as possible or shield 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 gel or other thermal conductive material to contact surface will enhance thermal performanc...

Страница 8: ...se phase phase Figure Figure Figure Figure 3 3 3 3 The connecting diagram of J1 J1 J1 J1 and J2 J2 J2 J2 J1 J1 J1 J1 Pin Pin Pin Pin Definition Definition Definition Definition 1 1 1 1 PWR PWR PWR PWR Control Control Control Controller ler ler ler power power power power supply supply supply supply output output output output The The The The pin pin pin pin is is is is Red Red Red Red LED LED LED ...

Страница 9: ...ternally connected connected connected connected RTN RTN RTN RTN is is is is internally internally internally internally connected connected connected connected to to to to B B B B 2 2 2 2 Two Two Two Two PWR PWR PWR PWR pins pins pins pins J1 14 J1 14 J1 14 J1 14 and and and and J2 1 J2 1 J2 1 J2 1 are are are are internally internally internally internally connected connected connected connected...

Страница 10: ... 3 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 4 4 4 4 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...

Страница 11: ...ser User User User s s s s Manual Manual Manual Manual V V V V 3 3 3 3 1 1 1 1 Page 10 Figure Figure Figure Figure 5 5 5 5 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 ...

Страница 12: ... V V V V 3 3 3 3 1 1 1 1 Page 11 Figure Figure Figure Figure 6 6 6 6 Standard Standard Standard Standard Wiring Wiring Wiring Wiring for for for for Controllers Controllers Controllers Controllers Rated Rated Rated Rated Higher Higher Higher Higher Than Than Than Than 72V 72V 72V 72V 12V 12V 12V 12V or or or or 24V 24V 24V 24V supply supply supply supply is is is is required required required requ...

Страница 13: ...onnected correctly Turn the PWR switch on The LED should blink then keeps on 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 Please verify wiring and voltage if it doesn t...

Страница 14: ...er properly installation the following minor maintenance is recommended in certain applications Remove power by disconnecting the battery starting with battery positive Discharge the capacitors in the controller by connecting a load such as a contactor 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...

Страница 15: ...tage and configuration 2 Over voltage at regeneration Controller will cut back or stop regeneration 1 3 Low voltage error 1 The controller will attempt to clear the fault code automatically after 5 second if battery voltage returns to normal 2 Check the battery voltage 3 Charge battery if necessary 1 4 Over temperature warning 1 The controller temperature is over 90ºC The controller will cut back ...

Страница 16: ...Throttle isn t zero when try to change direction The controller won t change drive direction if throttle isn t zero Also it won t change direction at high speed The controller will wait throttle and speed close to zero before change direction 4 1 Over voltage at startup or regeneration The controller won t drive motor if detect overvoltage at power up It will cut back regen current or stop regen a...

Страница 17: ...ser User s s s s Manual Manual Manual Manual V V V V 3 3 3 3 1 1 1 1 Page 16 Contact Contact Contact Contact Us Us Us Us Kelly Kelly Kelly Kelly Controls Controls Controls Controls LLC LLC LLC LLC Home Home Home Home Page Page Page Page http www KellyController com E mail E mail E mail E mail Support KellyController com Phone Phone Phone Phone 01 224 637 5092 ...

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