Kelly KBL24101 User manual

Kelly

Kelly KBL

KBL

KBL Brushless

Brushless

Brushless Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Manual V

V

V 3

3

3 .

.

. 1

1

Kelly

Kelly KBL

KBL

KBL Brushless

Brushless

Brushless Motor

Motor

Controller

Controller User

User

’

s

s Manual

Manual

Devices

Devices Supported:

Supported:

Rev. 3. 1

Oct / 200 8

KBL

KBL 24

24

24 101

101

KBL

KBL 3610

3610

3610 1

1

KBL

KBL 2415

2415

2415 1

1

KBL

KBL 36

36

36 1

1

1 5

5

5 1

1

KBL

KBL 24201

24201

KBL

KBL 362

362

362 01

01

KBL

KBL 243

243

243 01

01

KBL

KBL 363

363

363 01

01

KBL48101

KBL72101

KBL48151

KBL72151

KBL48201

KBL72201

KBL48301

KBL72301

KBL48

KBL48 4

4

4 01

01

01 B

B

KBL72

KBL72 4

4

4 01

01

01 B

B

KBL48

KBL48 5

5

5 01

01

01 B

B

KBL72

KBL72 5

5

5 01

01

01 B

B

KBL48

KBL48 6

6

6 01

01

01 B

B

KBL72

KBL72 6

6

6 01

01

01 H

H

KBL

KBL 12151H

12151H

KBL

KBL 1

1

1 415

415

415 1H

1H

KBL

KBL 12221H

12221H

KBL

KBL 1

1

1 425

425

425 1H

1H

KBL

KBL 12251H

12251H

KBL

KBL 12401H

12401H

Kelly

Kelly KBL

KBL

KBL Brushless

Brushless

Brushless Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Manual V

V

V 3

3

3 .

.

. 1

1

Page 1

Contents

Kelly 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 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Table 1: LED CODES ......................................................................................14

Green LED Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Red LED Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Contact Us: ..................................................................................................... 16

Kelly

Kelly KBL

KBL

KBL Brushless

Brushless

Brushless Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Manual V

V

V 3

3

3 .

.

. 1

1

Page 2

Chapter

Chapter 1

1

1 Introduction

Introduction

1.1

1.1 Overview

Overview

The manual introduce s Kelly BLDC motor controller features, installation and maintenance.

R ead 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 control s for golf

cart, go-cart, electric motorcycle, forklift, hybrid vehicle , electrical vehicle, electric boat, as well

as industry motor speed or torque control. It uses high power MOSFET, PWM to achieve

efficiency 9 9 % in most cases. Powerful microprocessor brings in comprehensive and precise

control to the controllers. It also allow s users to set parameters, conduct tests, and obtain

diagnostic information quickly and easily.

Kelly

Kelly KBL

KBL

KBL Brushless

Brushless

Brushless Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Manual V

V

V 3

3

3 .

.

. 1

1

Page 3

Chapter

Chapter 2

2

2 Features

Features

Features and

and

and Specifications

Specifications

2.1

2.1 General

General

General functions

functions

(1)

Extended fault detection and protection. LED flashing for fault code.

(2)

Monitoring battery voltage

.

It will s top driving if battery voltage is too high

.

It will cut back

then stop driving if voltage is going too low.

(3)

Built-in current loop and over current protection.

(4)

Controller temperature measurement and protection

(5)

Current cutback at low temperature and high temperature to protect battery and controller.

The current will ramp down quickly if controller temperature is higher than 90C, and

shutdown at 100C. Low temperature current ramping down usually starts at 0C.

(6)

The controller keeps monitoring voltage during regen. It will cut back current then cut off

regen if voltage is going too high.

(7)

Configurable to limit max reverse speed 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 c ontactor driver. Cut off the power if any fault detected

.

(14)

Current meter to display both drive and regen current. Save shunt!

(15)

Configurable b oost switch

.

Output the maximum current achievable if the switch is

enable d and turned on.

(16)

Configurable t urbo switch

.

Limiting max power to half if the switch is enable d and turned

on.

(17)

Configurable max reverse power to half.

(18)

Enhanced regen brake function. Novel ABS technique provides powerful and smooth

regen.

(19)

Configurable 12V brake signal input, in lieu of motor temperature sensor.

(20)

Optional joystick throttle. Single 0-5V signal for both forward and reversing.

(21)

Motor over temperature detection and protection, with recommended thermistor .

(22)

3 hall position sensor inputs

.

Open collector, pull up provided.

(23)

Optional CAN bus.

(24)

Optional supply voltage 8V- 3

0V.

Caution! Regeneration has braking effect, but can't replace mechanical brake. Mechanical

brake is required to stop your vehicle. Regen isn

’

t a safety feature! Controller may stop regen

to protect itself (not you!).

Kelly

Kelly KBL

KBL

KBL Brushless

Brushless

Brushless Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Manual V

V

V 3

3

3 .

.

. 1

1

Page 4

2.2

2.2 Features

Features

1)

Intelligence with powerful microprocessor.

2)

Synchrono u s rectification, ultra low drop, fast PWM to achieve very high efficiency.

3)

Current limit and torque control.

4)

Battery current limiting available, doesn ’ t affect taking off performance.

5)

Low EMC.

6)

LED fault code help s user debugging.

7)

Battery protection: current cut back, shutdown and warning at high or low battery.

8)

Thermal enhanced rugged aluminum housing. Rugged connectors.

9)

Thermal protection: current cut back on low temperature and high temperature to protect

battery and controller.

10)

Configurable 60-degree or 120-degree hall position sensor.

11)

Support any number of poles.

12)

Up to 60000 electric 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 Specifications

Specifications

•Frequency of Operation: 16.6kHz.

•Standby Battery Current: < 2mA.

•5V Sensor Supply Current: 40mA.

•Supply Voltage, PWR, 18V to 90V.

•Supply Current, PWR, 150mA.

•Operating Voltage, B+, 18V to 1.25*Nominal Voltage.

•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: 0C to 50C (controller case temperature).

•Operating Temperature Range: -30C to 90C, 100C shutdown (controller case temperature).

•Motor Current Limit, 1 minute: 100A / 150A / 200A / 300A, depending on model.

•Motor Current Limit, continuous: 50

A

/ 75

A

/ 1 0 0A / 150A , depending on model.

•Max Battery Current : Configurable .

•Supply Voltage, 8-30V for Controllers Rated Higher Than 72V.

Kelly

Kelly KBL

KBL

KBL Brushless

Brushless

Brushless Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Manual V

V

V 3

3

3 .

.

. 1

1

Page 5

2.4

2.4 Name

Name

Name Regulation

Regulation

The nam e regulation of Kelly BLDC motor controller s :

The eigh th 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 controller.

KBL48101

Kelly

Kelly KBL

KBL

KBL Brushless

Brushless

Brushless Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Manual V

V

V 3

3

3 .

.

. 1

1

Page 6

Chapter

Chapter 3

3

3 Wiring

Wiring

Wiring and

and

and Installation

Installation

3.1

3.1 Mounting

Mounting

Mounting the

the

the 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 performance.

Sufficient heat sink and airflow are required for high power application.

The case outline and mounting hole dimensions are shown in Figure 1.

Tall: 62 millimeters

Figure

Figure 1:

1:

1: mounting hole dimensions ( dimensions in millimeter s)

Kelly

Kelly KBL

KBL

KBL Brushless

Brushless

Brushless Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Manual V

V

V 3

3

3 .

.

. 1

1

Page 7

3.2

3.2 Connections

Connections

3.2.1

3.2.1 Front

Front

Front Panel

Panel

Panel of

of

of BLDC

BLDC

BLDC Motor

Motor

Motor Controller:

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 .

Figure

Figure 2:

2:

2: Front panel of BLDC motor controller

B+:

B+: battery

battery

battery positive

positive

B-:

B-: battery

battery

battery negative

negative

A:

A: Output

Output

Output U/1/A

U/1/A

U/1/A phase

phase

B:

B: Output

Output

Output V/2/B

V/2/B

V/2/B phase

phase

C:

C: Output

Output

Output W/3/C

W/3/C

W/3/C phase

phase

Figure

Figure 3:

3:

3: The connecting diagram of J1

J1

J1 and J2

J2

J1

J1 Pin

Pin Definition

Definition

1-

1- PWR

PWR

PWR :

:

: Control

Control

Control ler

ler

ler power

power

power supply

supply

supply (output).

(output).

(output). The

The

The pin

pin is

is

is Red

Red

LED

LED for

for

for S/N

S/N

S/N less

less

less :08XXXXXX.

:08XXXXXX.

2-

2- Current

Current

Current meter.

meter.

meter. <200mA

<200mA

3-

3- Main

Main

Main contactor

contactor

contactor driver.

driver.

driver. <200mA

<200mA

4-

4- Alarm:

Alarm:

Alarm: To

To

To drive

drive

drive reverse

reverse

reverse beeper.

beeper.

beeper. <200mA

<200mA

5-

5- RTN:

RTN:

RTN: Signal

Signal

Signal return

return

6-

6- Green

Green

Green LED:

LED:

LED: Running

Running

Running indication

indication

7-

7- RTN:

RTN:

RTN: Signal

Signal

Signal return

return

8-

8- RS232

RS232

RS232 receiv

receiv

receiv er

er

9-

9- RS232

RS232

RS232 transmitt

transmitt

transmitt er

er

Kelly

Kelly KBL

KBL

KBL Brushless

Brushless

Brushless Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Manual V

V

V 3

3

3 .

.

. 1

1

Page 8

10-

10- CAN

CAN

CAN bus

bus

bus high

high

11-

11- CAN

CAN

CAN bus

bus

bus low

low

12-

12- Reserved

Reserved

13-

13- RTN:

RTN:

RTN: Signal

Signal

Signal r

r

r eturn,

eturn,

eturn, or

or

or power

power

power supply

supply

supply return

return

14-

14- Red

Red

Red LED:

LED:

LED: F

F

F ault

ault

ault code

code

code .The

.The

.The pin

pin is

is

is PWR

PWR

PWR for

for

for S/N

S/N

S/N less

less

less :08XXXXXX.

:08XXXXXX.

J2

J2 Pin

Pin Definition

Definition

1-

1- PWR

PWR

PWR :

:

: Control

Control

Control ler

ler

ler power

power

power supply

supply

supply (input)

(input)

2-

2- RTN:

RTN:

RTN: Signal

Signal

Signal r

r

r eturn,

eturn,

eturn, or

or

or power

power

power supply

supply

supply return

return

3-

3- RTN:

RTN:

RTN: Signal

Signal

Signal r

r

r eturn

eturn

4-

4- Motor

Motor

Motor temperature

temperature

temperature input.

input.

5-

5- Throttle

Throttle

Throttle analog

analog

analog input,

input,

input, 0-5V

0-5V

6-

6- B

B

B rake

rake

rake analog

analog

analog input

input

input ,

,

, 0-5V

0-5V

7-

7- 5V:

5V:

5V: 5V

5V

5V supply

supply

supply output.

output.

output. <40mA

<40mA

8-

8- Throttle

Throttle

Throttle switch

switch

switch input

input

9-

9- R

R

R everse

everse

everse switch

switch

switch input

input

10-

10- Brake

Brake

Brake switch

switch

switch input

input

11-

11- Hall

Hall

Hall phase

phase

phase C

C

12-

12- Hall

Hall

Hall phase

phase

phase B

B

13-

13- Hall

Hall

Hall phase

phase

phase A

A

14-

14- RTN:

RTN:

RTN: Signal

Signal

Signal r

r

r eturn

eturn

Notes:

1.

1. All

All

All RTN

RTN

RTN pins

pins

pins are

are

are internally

internally

internally connected.

connected.

connected. RTN

RTN

RTN is

is

is internally

internally

internally connected

connected

connected to

to

to B-

B-

2.

2. Two

Two

Two PWR

PWR

PWR pins,

pins,

pins, J1-14

J1-14

J1-14 and

and

and J2-1,

J2-1,

J2-1, are

are

are internally

internally

internally connected.

connected.

connected. It

It

It ’

’

’ s

s

s recommended

recommended

recommended to

to

to use

use

J1-14

J1-14 to

to

to supply

supply

supply peripherals.

peripherals.

peripherals. Twist

Twist

Twist peripheral

peripheral

peripheral wires

wires

wires with

with

with PWR

PWR

PWR is

is

is the

the

the best

best

best for

for

for EMC.

EMC.

Recirculation

Recirculation diodes

diodes

diodes are

are

are provided

provided

provided in

in

in the

the

the controller

controller

controller for

for

for main

main

main contactor

contactor

contactor coil,

coil,

coil, alarm

alarm

alarm and

and

meter

meter drivers.

drivers.

3.

3. Switch

Switch

Switch to

to

to return

return

return is

is

is active.

active.

active. Open

Open

Open switch

switch

switch is

is

is inactive

inactive

Caution:

Caution: Make

Make

Make sure

sure

sure all

all

all connections

connections

connections are

are

are correct

correct

correct before

before

before apply

apply

apply power.

power.

power. O

O

O therwise

therwise

therwise it

it

it may

may

may damage

damage

the

the controller!

controller!

controller! Please

Please

Please securely

securely

securely wire

wire

wire B-

B-

B- before

before

before applying

applying

applying power.

power.

power. It's

It's

It's preferred

preferred

preferred to

to

to place

place

contactor

contactor or

or

or breaker

breaker

breaker on

on

on B+.

B+.

B+. Don't

Don't

Don't connect

connect

connect GND

GND

GND to

to

to B-.Please

B-.Please

B-.Please place

place

place precharge

precharge

precharge resistor

resistor

resistor on

on

on any

any

breaker!

breaker! It

It

It can

can

can cause

cause

cause damage

damage

damage without

without

without it!!!

it!!!

Kelly

Kelly KBL

KBL

KBL Brushless

Brushless

Brushless Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Manual V

V

V 3

3

3 .

.

. 1

1

Page 9

3.2.2

3.2.2 Wiring

Wiring

Wiring of

of

of BLDC

BLDC

BLDC Motor

Motor

Motor Controller

Controller

Figure

Figure 4:

4:

4: Standard

Standard

Standard Wiring

Wiring

Wiring for

for

for Controllers

Controllers

Controllers Rated

Rated

Rated Equal

Equal

Equal or

or

or Lower

Lower

Lower Than

Than

Than 72V.

72V.

Kelly KBL24101 User manual

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