Kelly KBS24051L User manual

Kelly KBS Brushless Motor Controller User’s Manual V 4.1
Kelly KBS-L Brushless Motor
Controller User’s Manual
Devices Supported:
KBS24051L
KBS24101L
KBS24121L
KBS36051L
KBS36101L
KBS48051L
KBS48101L
KBS48121L
KBS72051L
KBS72101L
KBS72121L
Rev.4.1
Jan. 2014

Kelly KBS Brushless Motor Controller User’s Manual V 4.1
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Contents
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...................................................................................................................... 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................................................................ 11
4.1 Step 1................................................................................................................................. 11
4.2 Step 2.................................................................................................................................13
4.3 Step 3.................................................................................................................................14
4.4 Step 4.................................................................................................................................15
4.5 Step 5.................................................................................................................................16
Chapter 5 Maintenance..........................................................................................16
5.1 Cleaning.............................................................................................................................16
5.2 Configuration.....................................................................................................................17
Table 1: LED CODES................................................................................................17
Contact Us:..................................................................................................................20

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Chapter 1 Introduction
1.1 Overview
This manual introduces the Kelly Small BLDC motor controllers’ features, their installation
and their maintenance. Read the manual carefully and thoroughly before using the controller. If
you have any questions, please contact the support center of Kelly Controls.
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 controllers. It also
allows users to adjust parameters, conduct tests, and obtain diagnostic information quickly and
easily.

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Chapter 2 Features and Specifications
2.1 General functions
(1) Extended fault detection and protection. The LED flashing pattern indicates the fault
sources.
(2) Monitoring battery voltage. It will stop driving if the battery voltage is too high and it will
progressively cut back motor drive power as battery voltage drops until it cuts out
altogether at the preset “Low Battery Voltage” setting.
(3) Built-in current loop and over current protection.
(4) Configurable motor temperature protection range.
(5) Current cutback at low temperature and high temperature to protect battery and controller.
The current begins to ramp down at 90℃case temperature, shutting down at 100℃.
(6) The controller keeps monitoring battery recharging voltage during regenerative braking,
progressively cutting back current as battery voltage rises then cutting off regen altogether
when voltage goes too high.
(7) Maximum reverse speed is configurable to half of the maximum forward speed.
(8) An RS232 port allows for configuration, programming and software upgrades using the
free Windows GUI with your PC.
(9) Provision of a +5 volt output to supply various kinds of sensors, including 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 current. Save shunt!
(15) Configurable boost switch. Enables the maximum output power achievable if the switch is
turned on.
(16) Configurable economy switch. Limits the maximum current to half if the switch is turned on.
(17) Maximum reverse power is configurable to half power.
(18) Enhanced regen brake function. A novel ABS technique provides powerful and smooth
regen.
(19) Configurable 12V brake signal input, in lieu of motor temperature sensor.
(20) Optional joystick throttle. A bi-symmetrical 0-5V signal for both forward and reversing.
(21) Configurable motor over-temperature detection and protection with the recommended
thermistor KTY84-130.
(22) 3 hall position sensor inputs. Open collector, pull up provided.
(23) Optional supply voltage 8V-30V.
Caution! Regeneration has braking effect but does not replace the function of a mechanical
brake. A mechanical brake is required to stop your vehicle. Regen IS NOT a safety feature!
Controller may stop regen, without warning, to protect itself or the battery(it won’t protect you!).

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2.2 Features
1) Intelligence with powerful microprocessor.
2) Synchronous rectification, ultra low drop, fast PWM to achieve very high efficiency.
3) Electronic reversing.
4) Voltage monitoring on 3 motor phases, bus, and power supply.
5) Voltage monitoring on voltage source 12V and 5V.
6) Current sense on all 3 motor phases.
7) Current control loop.
8) Hardware over current protection.
9) Hardware over voltage protection.
10) Configurable limit for motor current and battery current.
11) Support torque mode, speed mode, and balanced mode operation.
12) Low EMC.
13) LED fault code.
14) Battery protection: current cutback, warning and shutdown at configurable high and low
battery voltage.
15) Rugged aluminum 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.
(Electric RPM = mechanical RPM * motor pole pairs).
21) Support three modes of regenerative braking: brake switch regen, release throttle regen,
0-5V analog signal variable regen.
22) Configurable high pedal protection: the controller will not work if high throttle is detected at
power on.
23) Current multiplication: Take less current from battery, output more current to motor.
24) Easy installation: 3-wire potentiometer will work.
25) Standard PC/Laptop computer to do programming. No special tools needed.
26) User program provided. Easy to use. No cost to customers.

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2.3 Specifications
•Frequency of Operation: 16.6kHz.
•Standby Battery Current: < 0.5mA.
•5V Sensor Supply Current: 40mA.
•Controller supply voltage range: PWR, 18V to 90V for controllers rated equal or lower than
72V. 8V to 30V for 24V controller.
•Supply Current, PWR, 30mA Typical.
•Configurable battery voltage range, B+. Max operating range: 18V to 1.25*Nominal Voltage.
•Standard Throttle 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℃to 50℃(controller case temperature).
•Operating Temperature Range: -30℃to 90℃,100℃shutdown (controller case temperature).
•Motor Current Limit, 10 seconds boost: 50A-120A ,depending on the model.
•Motor Current Limit, continuous: 20A-50A ,depending on the model.
•Max Battery Current :Configurable.
2.4 Name Regulation
The name regulation of Kelly BLDC motor controllers:

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Chapter 3 Wiring and Installation
3.1 Mounting the Controller
The controller can be oriented in any position which should be as clean and dry as possible,
and if necessary, shielded 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 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 Figure 1.
Height: 41 millimeters
Figure 1: KBS-L mounting holes’ dimensions (dimensions in millimeters)

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3.2 Connections
3.2.1 Pin definition of KBS-L/KBS-X 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

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Male Connector Pin Definition
(14) REV_SW: Reverse switch input. Deep Blue
(6) RTN: Signal return or power supply return. Black
(11) Green-LED: Running indication. Dark Gray
(12) Red-LED: Fault code. White
(9) Relay: Main contactor driver, <200mA. Blue
(7) PWR: Controller power supply (input). Pink
(10) Alarm: To drive reverse beeper, <200mA. Yellow
Female Connector Pin Definition
(15) Micro_SW: Throttle switch input. Gray
(3) Throttle: Throttle analog input, 0-5V. Dark Green
(1) BRK2: 12V Brake switch input or Motor temperature sensor input. Raddle.
(20) RTN: Signal return. Black
(8) Meter: Current meter, <200mA. Dark Blue
(13) BRK_SW: 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 and has been
double checked. Wiring faults will damage the controller.
•Ensure that the B- wiring is securely and properly connected before applying power.
•The preferred connection of the system contactor or circuit breaker is in series with the B+
line.
•All contactors or circuit breakers in the B+ line must have precharge resistors across their
contacts. Lack of even one of these precharge resistors may severely damage the controller
at switch-on.
3.2.2 Wiring of KBS-LController
3.2.2.1 Standard wiring of KBS-L controller

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Figure 3: KBS-L controller standard wiring
(Battery voltage can be used for controller supply)