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Kelly KHB High Power Brushless Motor Controller User

’

s Manual

V 4.5

Page 14

Chapter 4 Maintenance

There are no user-serviceable parts inside the controllers. Do not attempt to open the

controller as this will void your warranty. However, periodic, exterior cleaning of the controller

should be carried out.

The controller is a high powered device. When working with any battery powered vehicle,

proper safety precautions should be taken that include, but are not limited to, proper training,

wearing eye protection, avoidance of loose clothing, hair and jewelry. Always use insulated

tools.

4.1 Cleaning

Although the controller requires virtually no maintenance after 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 down
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.

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 controller may display fault code in some
conditions, but it doesn't affect programming or configuration.

Use a straight through RS232 cable or Kelly USB To RS232 Converter to connect to a host
computer. Provide 10V-30V (either J2 pin1 or J1 pin1) to PWR. Wire power supply return to
any RTN pin, isolated from B-.

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 Configuration

Software!

•

Configuration software will be regularly updated and published on the website. Please
Update your Configuration Software regularly. You must uninstall the older version
before updating.

•

When setting "Hall Sensor Type" in GUI, do not use "Auto-Check". This has been
deleted from the newer configuration software versions.

Содержание KHB Series

Страница 1: ...ser s Manual V 4 5 Kelly KHB High Power Brushless Motor Controller User s Manual Devices Supported KHB72601 KHB12101 KHB72701 KHB14201 KHB72101 KHB14301 KHB12151 KHB14401 KHB12201 KHB14601 KHB12251 KHB12301 KHB12401 KHB12601 KHB12801 Rev 4 5 Dec 2016 ...

Страница 2: ...Features 4 2 3 Specifications 5 2 4 Naming Regulations 5 Chapter 3 Wiring and Installation 6 3 1 Mounting the Controller 6 3 2 Connections 8 3 2 1 Front Panel and back panel of KHB Motor Controller 8 3 2 2 Wiring of KHB Motor Controller 12 3 3 Communication Port 13 3 4 Installation Check List 13 Chapter 4 Maintenance 14 4 1 Cleaning 14 4 2 Configuration 14 Table 1 LED CODES 15 Contact Us 17 ...

Страница 3: ...support center of Kelly Controls Kelly s programmable motor controllers provide high efficient smooth and quiet controls for electric motorcycles forklifts hybrid vehicles electric vehicles and electric boats 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...

Страница 4: ... 5V inputs that default to throttle input brake input and motor temperature input 11 Provision of a 5 volt output to supply various kinds of sensors including Hall effect type 12 Main contactor driver Cutting off the power if any fault is detected 13 Current meter to display both drive and regen current Save shunt 14 3 hall position sensor inputs Open collector pull up provided 15 Maximum reverse ...

Страница 5: ... or water cooling 17 Rugged high current terminals and rugged aviation connectors for small signal 18 Thermal protection current cut back warning and shutdown at high temperature 19 Configurable 60 degree or 120 degree hall position sensors 20 Support motors with any number of poles Up to 40 000 electric RPM standard Optional high speed 70 000 ERPM and ultra high speed 100 000 ERPM Electric RPM me...

Страница 6: ...controller rated equal 144V 7 Standard Throttle Input 0 5 Volts 3 wire resistive pot 1 4 Volts hall active throttle 8 Analog Brake and Throttle Input 0 5 Volts Producing 0 5V signal with 3 wire pot 9 Reverse Alarm Main Contactor Coil Driver Meter 10 Full Power Operating Temperature Range 0 to 50 controller case temperature 11 Operating Temperature Range 30 to 90 100 shutdown controller case temper...

Страница 7: ...r should be fastened to a clean flat metal surface with six 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 of KHB Controllers Height 84 millimeters Length 218 millimeters Figure ...

Страница 8: ...ontroller User s Manual V 4 5 Page 7 Height 84 millimeters Length 286 millimeters Figure 2 KHB mounting holes dimensions dimensions in millimeters Controller models with above dimension KHB72701 KHB72101 KHB12601 KHB12801 KHB14301 KHB14401 ...

Страница 9: ... Brushless Motor Controller User s Manual V 4 5 Page 8 Height 84 millimeters Length 328 millimeters Figure 3 KHB mounting holes dimensions dimensions in millimeters Controller models with above dimension KHB14601 KHB12101 ...

Страница 10: ...tal bars in front panel and two plugs J1 J2 in back panel are provided for connecting to the battery motor and control signals shown as Figure 4 6 and 8 Figure 4 Front panel of KHB motor controller B battery positive B battery negative A U Output A U phase B V Output B V phase C W Output C W phase Figure 5 Front panel of KHB14601 KHB12101 motor controller ...

Страница 11: ...Kelly KHB High Power Brushless Motor Controller User s Manual V 4 5 Page 10 Figure 6 Back panel of KHB motor controller Figure 7 Back panel of KHB14601 KHB12101 motor controller ...

Страница 12: ...Controller power supply input 2 RTN Signal return or power supply return 3 RTN Signal return 4 Motor temperature input 5 Throttle analog input 0 5V 6 Brake analog input 0 5V 7 5V 5V supply output 40mA 8 Micro_SW Throttle switch input 9 Reversing switch input 10 Brake switch input 11 Hall phase C 12 Hall phase B 13 Hall phase A 14 RTN Signal return Notes 1 All RTN and GND pins are internally connec...

Страница 13: ...Kelly KHB High Power Brushless Motor Controller User s Manual V 4 5 Page 12 3 2 2 Wiring of KHB Motor Controller Figure 9 Standard Wiring for KHB Controllers 12V or 24V battery supply is required ...

Страница 14: ...orrectly Turn on the PWR switch the Red flashes once and the Green is off After the start up delay normally the Red will stay off and the Green will turn on If there is error the Red LED will flashes for fault codes If the S N less 11xxxxxx Turn on the PWR switch the Red flashes once and the Green is on Normally the Red will stay off If there is error the Red LED will flashes for fault codes The f...

Страница 15: ... should be wiped down 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 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 ...

Страница 16: ...ll clear after 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 sen...

Страница 17: ...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 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 an...

Страница 18: ...Kelly KHB High Power Brushless Motor Controller User s Manual V 4 5 Page 17 Contact Us Kelly Controls Home Page http www KellyController com E mail Support KellyController com Phone 01 224 637 5092 ...

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