Kelly Motor Controller - Electrathon of Tampa Bay
Contents
1. x ex 12 Table 1 LED Pcr 13 Contact HEC RECON SEE ARREST RECEN 15 Page 1 Kelly KBL Series Brushless Motor Controller User s Manual V 2 0 Chapter 1 Introduction 1 1 Overview The manual introduces Kelly BLDC motor controller features installation and maintenance 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 electrical vehicles like golf cart go cart electric motorcycle fork lift hybrid vehicle as well as electric boat and industry motor speed control It uses high power MOSFET fast PWM to achieve efficiency gt 98 in most cases Powerful microprocessor brings in comprehensive and precise control to the controllers It also allows users to set parameters conduct tests and obtain diagnostic information quickly and easily Page 2 Kelly KBL Series Brushless Motor Controller User s Manual V 2 0 Chapter 2 Main Features and Specifications 2 1 General functions 1 Extended fault detection and protection LED flashing for fault code 2 Monitoring battery voltage Stop driving if battery voltage is too high or too low 3 Built in current loop and over current protection 4 Controller temperature measurement and protection 5 The current will ram2. pued zuo 18039 j29uuoa no amp UIJ M CCI E8ALM 0 mop way peuondo sr Aq st sng NV uq yomg Y APT 2 M i g uo yeaq 10 jnd 4249N Surm 13470 AUB g M S IVd AS 0 posn oq ue 49joueriuo oq 4310N 19 0007 TH Landing Ac ND L 9 NV yeg qaos p wey p GND C ND 100W 00010 AIZZN Y IAI Z TNVO LH TNVO WNVOOI WNVO XL CECSW 6 XIXC CXI XU TETSU 8 XUTETXU 109915 9 ND c CAT P I AC Vulg CTT 09945 xx At Vulg CAT xxx BLDC controller preferred wiring Figure 5 Page 10 V2 0 9 soun uq oue TTT PUN we pauuo vy CCEOS ADI 03 appe jeuon do st LI y y apejop Aq s15nq NYJ y ANANA 1200002 UNG gp uoprarq nd waay Aue aroq g atm Apamnaos eag AS Qindyno 0 posn aq wes ueriumog 310N puo Diode 200V 3A Precharge Resistor 300 2 10W Main Contactor asn WZ yomg JON Kelly KBL Series Brushless Motor Controller User s Manual The standard wiring o
3. on face penal to a host computer Provide 18V to 90V to PWR either J2 pin1 or J1 pin14 Wire power supply ground to any GND pin e Do not connect B throttle and so on The controller may display fault code but it doesn t affect programming or configuration Page 13 Kelly KBL Series Brushless Motor Controller User s Manual Table 1 LED CODES Green LED Codes LED Code Explanation Solution Green Off No power or not 1 Check if all wires are correct operating 2 Check fuse and power supply Green On Normal operation That s great You got solution Green and Red LED Keep On 1 Software is upgrading 2 The controller is damaged Please contact Kelly for warrantee Red LED Codes LED Code Explanation Solution 1 2 on Over voltage error 1 Battery voltage is higher than max operating voltage of the controller Please check the battery voltage 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 return to normal 2 Check the battery voltage 3 Charge battery if necessary 1 4 aana Over temperature 1 The controller temperature is over 90 The warning controller will cut back current in the case Stop or reduce output to ensure the temperature fall 2 Improve heat sink or airflow 2
4. 1 Motor RPM over 1 After 2 seconds which controller start to output low motor rotate speed doesn t reach 25 electric RPM the controller will limit output current When motor rotate speed beyond 25 electric RPM output current won t be limited 2 2 aa nm Internal voltage 1 Check if the B and PWR voltage are correct fault refer to B or GND 2 Please check load on 5V supply 3 The controller is damaged Please contact Kelly for warrantee 2 3 nnn Over temperature 1 The controller temperature is over 100 C Controller stops driving in order to protect itself 2 Stop driving and wait for temperature fall The controller will restart if temperature drops below 80 C Page 14 V2 0 Kelly KBL Series Brushless Motor Controller User s Manual V 2 0 2 4 aaan Throttle error at 1 The throttle signal is higher than configured power up dead zone at power on 2 The fault will disappear if restart or release throttle 3 1 oon n Frequent reset 1 The controller will stop driving after detect too many resets 2 mostly because of overcurrent protection 3 Restart will clear the error 4 Please contact Kelly if it happens repeatedly 3 2 moo nn Internal reset Reset caused by over current or so It is normal if occurring occasionally 3 4 uum Throttle isn t zero The controller won t change drive direction if when try to throttle isn t zero Also it won t change di
5. Kelly KBL Series Brushless Motor Controller User s Manual V 2 0 Kelly KBL Series Brushless Motor Controller User s Manual Devices Supported KBL24101 KBL36101 KBL24151 KBL36151 KBL24201 KBL36201 KBL24301 KBL36301 KBL48101 KBL72101 KBL48151 KBL72151 KBL48201 KBL72201 KBL48251 KBL72251 KBL48301 72301 KBL12151H KBL12221H Rev 2 0 Jan 2008 Kelly KBL Series Brushless Motor Controller User s Manual V 2 0 Contents vt oun sob ee ee bb oes bh Rod EE oes cow 2 1 1 OVQPVIDW nioae 2 Chapter 2 Main Features and 1 1 1 5 3 221 General TUNCU ONS edad pipea RARUS T ESASPERSa SG SEES PES 3 NCBI m Cr 3 i0 Specifications whe edi 4 dk Modele ad sudes eed dico p dicio o adici 5 Chapter 3 Wiring and 1 11 1 5 3 1 Mounting the 11 5 9 4 CODDBCLIODB i PERS HES ea sedent 6 3 3 Installation Checklist 11 Chapter 4 1 12 A 12 4 2 1 1
6. ase C Output W 3 C phase oW Figure 3 The connecting diagram of J1 and J2 4100 o Definition 14 12 3 13 O 1 Red LED Fault code 8 7 2 e 3 Reserved 5 4 Alarm To drive reverse beeper 7 5 5 GND Signal return 6 Green LED Running indication 7 GND Signal return 8 RS232 receiver 9 RS232 transmitter 10 CAN bus high 11 CAN bus low 12 Reserved 13 GND Signal return or power supply ground 14 PWR Controller power supply J2 Pin Definition Page 7 Kelly KBL Series Brushless Motor Controller User s Manual V 2 0 1 PWR Controller power supply 2 GND Signal return or power supply ground 3 GND Signal return 4 Motor temperature input 5 Throttle analog input 0 5V 6 Brake analog input 0 5V 7 5V 5V supply output 8 Throttle switch input 9 Reverse switch input 10 Brake switch input 11 Hall phase C 12 Hall phase B 13 Hall phase A 14 GND Signal return Notes All GND pins are internally connected GND is internally connected to B 2 Two PWR pins J1 14 and J2 1 are internally connected It s recommended to use J1 14 to supply peripherals like alarm and meters Twist peripheral wires with PWR is the best for EMC Recirculation diodes are provide in the controller for alarm and meter drivers 3 Switch to ground is active Open switch is inactive Caution Make sure all connections are correct before app
7. ed aluminum housing Rugged connectors Thermal protection Current cut back on low temperature and high temperature to protect battery and controller Compatible with 60 degree or 120 degree hall position sensor eSupport any number of poles Up to 60000 electric RPM electric RPM mechanical RPM motor poles High pedal protection Disable operation if power up with non zero throttle Page 3 Kelly KBL Series Brushless Motor Controller User s Manual V 2 0 Brake switch is used to start regen 0 5V brake signal is used to command regen current 2 3 Specifications Frequency of Operation 16 6kHz Standby Current less than 3 mA Supply Voltage PWR 18V to 90V Supply Current PWR 150mA Operating Voltage B 18V to 1 25 Norminal Analog Brake and Throttle Input 0 5 Volts Reverse alarm 150mA Full Power Operating Temperature Range OC to 50C controller case temperature Operating Temperature Range 30C to 90C 100C shutdown controller case temperature Armature Current Limit 1 minute 100A 150A 200A 250A 300A Armature Current Limit Continuous 60A 90A 120A 150A 180A Page 4 Kelly KBL Series Brushless Motor Controller User s Manual V 2 0 2 4 Model The naming regulation of the Kelly BLDC motor controller model KBL48101 The eighth letter represents whether the controller with regeneration 0 represents non regeneration 1 represents with regeneration The si
8. f KBL12151H KBL12221H Figure 6 Page 11 Kelly KBL Series Brushless Motor Controller User s Manual V 2 0 3 2 3 Communication Port RS232 port of controller is provided to communicate with host computer for calibration and configuration O oO O QO Figure 6 standard RS232 interface 3 3 Installation Check list Before operating the vehicle complete the following checkout procedure Use LED code as a reference The LED codes are 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 directly in front of or behind the vehicle during the checkout Make 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 LED should blink then keeps on 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 direction and operate the throttle The motor should spin in the selected direction Please verify wiring and voltage if it doesn t Also check fuse The motor should run faster with increasing throttle If not refer to Table 1 LED code and correct the fault according to the code Take the vehicle off the blocks and drive it in a clear area It should ha
9. ly power Otherwise it may damage the controller Please securely wire B before applying power Never put contactor or break on B Don t connect GND to B Page 8 V2 0 Kelly KBL Series Brushless Motor Controller User s Manual 3 2 2 Standard Wiring of BLDC Motor Controller Precharge Resistor 30002 10W Battery Fuse Main Contactor POLE COIL Diode 100V 1A 5 Fuse Key Switch poonpoa oq JIM ssoujqariq pued zuo QAT IP AAT JEUX j20uu02 AA TUL ESALM 0 ouoNdo sr 1 yntjop Aq poyejndodap st snq gt g 0 AN5 1290002 uo T YENG 10 nd AUt ATALNIIS asto d 0 1ndjno oj pasn oq ue 19joumerjuojod 4 10N 100W TH 1910410 T TH OIMS 9g Linding As 9 copo C ND jeuondg 1 Z NVO H HNVOOL XL TETSY 6 NUCETSA 8 ND L 1419910 9 ND lt wey p C CAT Pee I NV H NV9 XUTEXA gt CAT PPA xxx iring BLDC controller standard wi Figure 4 Page 9 V2 0 Kelly KBL Series Brushless Motor Controller User s Manual Precharge Resistor 3009 1 0W Battery Fuse Main Contactor y POLE COIL g 0 INS 199uuo9 Diode 100V 1A aq JIM
10. ontroller com E mail Support KellyController com Phone 001 224 637 5092 Page 16
11. p down quickly if controller temperature is higher than 90C and shutdown at 100C Low temperature current ramping down usually starts at OC 6 The controller keeps monitoring voltage during regen It will cut back current or stop regen if voltage is too high 7 Configurable to limit max reverse speed to half of max forward speed 8 Two RS232 ports One for configuration the other for application 9 Configurable and programmable with RS 232 Software upgradeable Windows GUI provided 10 Provide 5V sensor supply 11 Reverse alarm output Recirculation diodes provided 12 Motor temperature detection and protection 13 _ 3 hall position sensor inputs Open collector The controller provides pull up 14 switch inputs Close to ground to activate Default to throttle switch brake switch and reverse switch 15 3 analog inputs 0 5V Default to throttle input brake input and motor temperature input 16 Optional CAN bus Caution Regeneration has braking effect but cant replace mechanical brake Mechanical brake 5 required to stop your vehicle Regen isnt a safety feature Controller may stop regen fo protect itself not you 2 2 Features Intelligence with powerful microprocessor Synchronos rectification ultra low drop fast PWM to achieve very high efficiency Current limit and torque control EMC Battery protection current cut back shutdown and warning at low battery Thermal enhanced rugg
12. rection at change direction high speed The controller will wait throttle and speed close to zero before change direction 4 1 mond mn Over voltage at The controller won t drive motor if detect startup or overvoltage at power up It will cut back regen regeneration current or stop regen if detect overvoltage during regen You may set overvoltage threshold with GUI The max threshold is about 1 25 times of controller rated voltage l e you may set threshold lower than 60V for 48V controller 4 2 nooo nu Hall sensor signal 120 degree hall motor produce the coding error belonging to 60 degree hall motor or 60 degree hall motor produce the coding belonging to 120 degree Needing user to set the hall angle to correct type through calibration software 4 3 Motor over 1 The motor temperature sensor beyond the temperature setting temperature the motor will stop outputing and waiting motor temperature to drop to original temperature then restart 2 Can change the temperature through calibration software 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 Page 15 Kelly KBL Series Brushless Motor Controller User s Manual V 2 0 Contact Us Kelly Controls LLC Home Page http www KellyC
13. ve smooth acceleration and good top speed Page 12 Kelly KBL Series Brushless Motor Controller User s Manual V 2 0 Chapter 4 Maintenance There are no user serviceable parts inside the controllers Do not attempt to open the controller Or you will damage it However clearing the controller exterior periodically should be necessary The controller is inherently a high power device When working with any battery powered vehicle proper safety precautions should be taken These include but are not limited to proper training wearing eye protection avoiding loose clothing and jewelry and using insulated wrenches 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 Discharge the capacitors in the controller by connecting a load such as a contactor coil or a horn across the controller s B and B terminals e Remove any dirt or corrosion from the bus bar area The controller should be wiped with a moist rag Be sure it is dry before reconnecting the battery Make sure the connections to the bus bars are tight Use two wrenches for this task in order to avoid stressing the bus bars the wrenches should be well insulated 4 2 Configuration You can configure the controller with a host computer through RS232 e Use straight RS232 cable connecting the 9pin connector
14. xth and seventh letters represent the max current divided by 10 The fourth and fifth letters represent the max voltaae The first three letters represent Kelly s BLDC motor controller Chapter 3 Wiring and Installation 3 1 Mounting the 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 performance Sufficient heat sink and airflow are required for high power application The case outline and mounting hole dimensions are shown in Figure 1 Page 5 Kelly KBL Series Brushless Motor Controller User s Manual V 2 0 PC Q R HO m om iJ c Cam T 9 130 146 Tall 62 millimeters Figure 1 mounting hole dimensions dimensions in millimeters 3 2 Connections 3 2 1 Front Panel of BLDC Motor Controller Five metal bars and two plugs J1 J2 are provided for connections to the battery motor and control signals in the front of the controller shown as Figure 2 Page 6 Kelly KBL Series Brushless Motor Controller User s Manual V 2 0 Figure 2 Front panel of BLDC motor controller B battery positive B battery negative A Output U 1 A phase B Output V 2 B ph
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