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Kelly KBS Brushle ss Motor Controller User

’s Manual

V 4.1

Kelly KBS Brushless Motor

Controller User’s Manual

Devices Supported:

KBS24051E KBS48051E

Rev.4.1

Dec. 2011

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Содержание KBS24051

Страница 1: ...roller User s Manual V 4 1 Kelly KBS Brushless Motor Controller User s Manual Devices Supported KBS24051 KBS48051 KBS24051E KBS48051E KBS24101 KBS48101 KBS24121 KBS48121 KBS36051 KBS72051 KBS36101 KBS72101 KBS72121 Rev 4 1 Dec 2011 ...

Страница 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 12 4 1 Step 1 12 4 2 Step 2 13 4 3 Step 3 14 4 4 Step 4 15 4 5 Step 5 16 Chapter 5 Maintenance 17 5 1 Cleaning 17 5 2 Configuration 17 Table 1 LED CODES 18 Contact Us 19 ...

Страница 3: ...tact the support center of Kelly Controls LLC 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 control...

Страница 4: ...cluding 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 curr...

Страница 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...

Страница 6: ...tle 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 ﹾ Ｃ to 50 ﹾ Ｃ controller case temperature Operating Temperature Range 30 ﹾ Ｃ to 90 ﹾ Ｃ 100 ﹾ Ｃshutdown controller case temperature Motor Current Limit...

Страница 7: ...inants 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 Fig...

Страница 8: ... 2 Connections 3 2 1 Pin definition of KBS 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 ...

Страница 9: ...W Brake switch input Brown 4 5V 5V supply 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...

Страница 10: ...Brushless Motor Controller User s Manual V 4 1 9 3 2 2 Wiring of KBS Controller 3 2 2 1 Standard wiring of KBS controller Figure 3 KBS controller standard wiring Battery voltage can be used for controller supply ...

Страница 11: ...ARS232 port is provided to communicate with host computer for calibration and configuration Figure 6 RS232 Interface 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 to stand d...

Страница 12: ...he 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 voltage and the fuse if it does not The motor should run 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 blo...

Страница 13: ...ional description If enabled and turn off foot switch controller will not operate 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 J2 8 J2 9 Enable Disable OFF OFF Neutral ON OFF Forward OFF ON Back ON ON Neutral Disable Enable OFF x Not operate ON OFF Forward ON ON Back Disable D...

Страница 14: ...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 acceleration Balanced mode brings fast response of the load and wide sp...

Страница 15: ...t 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 Speed In Reverse Val...

Страница 16: ...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 Suggestion ...

Страница 17: ...l 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 Temperatur...

Страница 18: ...er 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 You can configure the controller with a host computer through either an RS232 or USB port Disconnect motor wiring from controller Do not con...

Страница 19: ...fter 5 seconds if battery volts 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 pha...

Страница 20: ...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 or 120 degree 4 3 Motor over temperature Motor temperature has exceeded the configured ma...

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