Kelly KBS48181E User manual

Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2
Kelly KBS-E Brushless Motor
Controller User’s Manual
Devices Supported:
Rev.1.2
Dec.2016
KBS48151E
KBS72151E
KBS48181E
KBS72181E
KBS48221E
KBS72221E

Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2
1
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...................................................................................................................... 10
3.3 Installation Check List......................................................................................................16
Chapter 4 Programmable Parameters................................................................ 17
4.1 Step 1.................................................................................................................................17
4.2 Step 2.................................................................................................................................18
4.3 Step 3.................................................................................................................................19
4.4 Step 4.................................................................................................................................20
4.5 Step 5.................................................................................................................................21
Chapter 5 Maintenance..........................................................................................22
5.1 Cleaning.............................................................................................................................22
5.2 Configuration.....................................................................................................................22
Table 1: LED CODES................................................................................................ 23
Contact Us:..................................................................................................................25

Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2
2
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.

Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2
3
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!).

Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2
4
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.

Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2
5
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, Meter: <200mA. Main Contactor Coil Driver<2A.
•Full Power Operating Temperature Range: 0℃to 70℃(MOSFET temperature).
•Operating Temperature Range: -40℃to 100℃(MOSFET temperature).
•Motor Current Limit, 10 seconds boost: 160A-260A ,depending on the model.
•Motor Current Limit, continuous: 80A-130A ,depending on the model.
•Max Battery Current :Configurable.
2.4 Name Regulation
The name regulation of Kelly BLDC motor controllers:

Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2
6
Kelly KBS-E Brushless Motor Controller
Model
10 seconds
Current(Amp)
Continuous
Current(Amp)
Voltage(Volt)
KBS48151E
160
80
24-48
KBS48181E
200
110
24-48
KBS48221E
260
130
24-48
KBS72151E
160
80
24-72
KBS72181E
200
110
24-72
KBS72221E
260
130
24-72
1.48V model: range of the max operating voltage is 18-60V.
2.72V model: range of the max operating voltage is 18-90V.
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 1,2,3.

Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2
7
Height: 41 millimeters
Figure 1:KBSXX151E mounting holes’ dimensions (dimensions in millimeters)

Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2
8
Height: 51.5 millimeters
Figure 2:KBSXX181E mounting holes’ dimensions (dimensions in millimeters)

Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2
9
Height: 58.5 millimeters
Figure 3:KBSXX221E mounting holes’ dimensions (dimensions in millimeters)

Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2
10
3.2 Connections
3.2.1 Pin definition of KBS-E Controller
Figure 4: waterproof connector
DJ7061Y-2.3-21 Pin Definition
(21) RTN:Signal return. Black
(5) 5V: 5V supply output,<40mA.Purple
(18) Hall A: Hall phase A. Yellow
(17) Hall B: Hall phase B. Dark Green
(16) Hall C: Hall phase C.Dark Blue

Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2
11
DJ7091Y-2.3-11 Pin Definition
(14) REV_SW: Reverse switch input. Orange
(6) RTN: Signal return or power supply return. Black
(12) FWD: Forward switch White
(11) 12V:12V Source Red
(9) Relay: Main contactor driver. Blue
(7) PWR: Controller power supply (input). Pink
(10) Alarm: To drive reverse beeper, <200mA. Yellow
DJ7091Y-2.3-21 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. Purple
(2) BRK_AN: Brake analog input, 0-5V. Dark Gray
(22) Reservation. Green
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.

Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2
12
3.2.2 Wiring of KBS-E Controller
3.2.2.1 Standard wiring of KBS-E controller
Figure 5: KBS-E controller standard wiring
(Battery voltage can be used for controller supply)

Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2
13
Figure 6:KBS-E F-N-R control wiring diagram

Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2
14
3.2.2.2 Optional wiring of KBS-E controller
The output signal of the pin is for Kelly current meter.
Figure 7: wiring of current meter pin
The 12V input signal of the pin supplies the second braking function of the controller.
Figure 8: Wiring of brake switch(12V): 12V is provided by external source.
Figure 9: Wiring of brake switch(12V): 12V is provided by KBS-X controller on pin11
Figure 10: Wiring of motor temperature sensor: pin1-Brk2 can be used as motor temperature
sensor port
Note:The motor temperature sensor item must be enabled in the user program for three kinds
of wiring diagrams.By default,Kelly controller supports KTY84-130 and KTY83-122
thermistors.Either of them can be chose in the user program.Motor temperature sensor and 12V
Brake switch used the same pin on pin1-Brk2.Both functions can not be used at the same time.

Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2
15
3.2.3 Communication Port
A RS232 port is provided to communicate with host computer for calibration and configuration.
Figure 11: RS232 Interface on KBS controller
Figure 12：SM-4P connector for communication interface on KBS-E controller

Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2
16
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 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 Green LED stay on steadily and Red LED turns off when the
controller operates normally. If this does not happen, check continuity of the PWR and
return.
•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. 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 blocks and drive it in a clear area. It should have smooth
acceleration and good power.

Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2
17
Chapter 4 Programmable Parameters
KBS Configuration program allow users to set parameters according to the vehicle actual
working environment so as to be at its best.
The default parameters of the controller are not recommended for all applications. Make
sure set the proper parameters before making any test to avoid danger.
4.1 Step 1
(1)Forward Switch
Value range: Enable and Disable
Functional description: If enabled, the Forward switch will be activated. Please see figure 4.1.
Suggestion: Set according to the practical situation, factory default is Disable.
(2)Foot Switch
Value range: Enable and Disable
Functional description: If enabled,the foot switch will be activated.The controller will not accept
the throttle signal if the foot switch is turned off. 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
FWD_SW
(12)
REV_SW
(14)
Foot
(15)
Enable
Disable
OFF
OFF
x
Neutral
OFF
ON
x
Reverse
ON
OFF
x
Forward
ON
ON
x
Neutral
Disable
Enable
x
OFF
OFF
Can’t operate
x
ON
OFF
Can’t operate
x
ON
ON
Reverse
x
OFF
ON
Forward
Disable
Disable
x
OFF
x
Forward
x
ON
x
Reverse
Note: X means can be on or off
Figure 4.1
(3)Throttle Sensor Type
Value range: 3-wire resistive pot, hall active throttle.
Functional description: Set throttle sensor type.
Suggestion: Set according to the practical situation, factory default is 1-4V throttle type.
(4)Throttle Effective Starting Point
Value range: 10%-40%
Functional description: Set throttle effective starting point

Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2
18
Suggestion: Set according to the practical situation, factory default is 10%.
(5)Throttle Effective Ending Point
Value range: 60%-100%
Functional description: Set throttle effective ending point
Suggestion: Set according to the practical situation, factory default is 90%.
(6)Max Motor Current
Value range: 20%-100%
Functional description: The max motor current is (The Value * Peak Current of the Controller).
Suggestion: Factory default is 100%.
(7)Max Battery Current
Value range: 20%-100%
Functional description: Set max battery current so as to protect battery. A lower value means a
lower battery output current and better protective effect. But excessively low value will affect
acceleration.
Suggestion: Factory default is 100%.
4.2 Step 2
(1)Start-up Delay Time
Value range: 0.0s~2.0s
Functional description: When power is on, set delay time to wait for stabilization of B+, a higher
value means a longer delay time.
Suggestion: Set according to the practical situation, factory default is 0.5s.
(2)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 speed
adjusting range. Speed mode brings smooth operation and wide speed adjusting range.
Suggestion: Set according to the practical situation, factory default is Torque mode.
(4)Under Voltage
Value range: Please see Figure 4.2
Functional description: Controller will not operate when battery voltage is lower than the value
so as to protect battery.
Suggestion: Set according to the practical situation.
(5)Over Voltage
Value range: Please see Figure 4.2
Functional description: Controller will not operate when battery voltage is higher than the value
so as to protect battery and controller.
Suggestion: Set according to the practical situation.

Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2
19
Controller Rated voltage
Under Voltage Range (V)
Over Voltage Range(V)
48V
18~60
18~60
72V
18~90
18~90
Figure 4.2
(6)Throttle Up/Down Rate
Value range: 0~100
Functional description: Pedal AD Sampling Frequency, a lower value means a shorter sampling
period and a faster respond rate.
Suggestion: Set according to the practical situation, factory default is 30.
(7)High Pedal Disable
Value range: Enable and Disable
Functional description: If enabled, the controller will detect the current pedal status at power up.
If throttle got effective output, the controller will report fault and not operate.
Suggestion: Set according to the practical situation, factory default is Enable.
(8)Releasing Brake High Pedal Disable
Value range: Enable and Disable
Functional description: If enabled, the controller will detect the current 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
Value range: Enable and Disable
Functional description: If enabled, the max reverse speed of the motor will be limited to half of
the max forward speed.
Suggestion: This function is available for firmware version 0103 or less. Set according to the
practical situation, factory default is Disable.
(3)Boost Function
Value range: Enable and Disable
Functional description: Please see figure 4.3
Suggestion: Set according to the practical situation, factory default is Disable.
(4)Economy Function
Value range: Enable and Disable
Functional description: Please see figure 4.3
Suggestion: Set according to the practical situation, factory default is Disable.