Kelly KEB Series User manual

Kelly Ebike Brushless DC Motor Controller User’s Manual V 3.3
Kelly KEB Brushless Motor
Controller User’s Manual
Devices Supported:
KEB48220
KEB48221
KEB48300
KEB48301
KEB48400
KEB48401
KEB48600
KEB48601
KEB72330
KEB72331
KEB72450
KEB72451
KEB72600
KEB72601
KEB72800
KEB72801X
Rev.3.3
Mar. 2011

Kelly Ebike Brushless DC Motor Controller User’s Manual V 3.3
Page 1
Contents
Chapter 1 Introduction.........................................................................................2
1.1 Overview.................................................................................................. 2
Chapter 2 Main Features and Specifications .......................................................3
2.1 General functions..................................................................................... 3
2.2 Features .................................................................................................. 4
2.3 Specifications .......................................................................................... 4
2.4 Models..................................................................................................... 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 Maintenance .....................................................................................11
4.1 Cleaning ................................................................................................ 11
4.2 Configuration......................................................................................... 11
Table 1: LED CODES........................................................................................12
Contact Us:........................................................................................................14

Kelly Ebike Brushless DC Motor Controller User’s Manual V 3.3
Page 2
Chapter 1 Introduction
1.1 Overview
This manual introduces the Kelly ebike brushless DC 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, LLC.
Kelly’s programmable KEB motor controllers provide efficient, smooth and quiet controls for
electric bicycles, electric motorcycles, scooters, etc. It outputs high taking off current, and
strictly limit battery current. It can work with relative small battery, but provide good acceleration
and hill climbing. It uses high power MOSFET’s and, PWM to achieve efficiencies of up to 99%.
In most cases, 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 Ebike Brushless DC Motor Controller User’s Manual V 3.3
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Chapter 2 Main Features and Specifications
2.1 General functions
(1) Extended fault detection and protection. LED flashing code indicates fault sources.
(2) Monitoring battery voltage. It will stop 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) Motor temperature input and protection. Configurable range.
(5) Cutting back current at low temperature and high temperature to protect battery and
controller. The current will ramp down quickly if controller temperature is higher than 90ﹾＣ,
and shut down at 100ﹾＣ. Low temperature current ramping down usually starts at 0ﹾＣ.
(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) Configurable and programmable with RS-232. Software upgradeable. Windows GUI
provided.
(9) Provide power supply (5V) for hall sensors and other sensors.
(10) 3 switch inputs: Default to throttle switch, brake switch and reversing switch. Closing to
ground is to activate.
(11) 3 analog inputs, 0-5V: Default to throttle input, brake input and motor temperature input.
(12) Configurable boost switch. Output can arrive at the maximum current if the switch is
enabled and turned on.
(13) Configurable turbo switch. Limit max power to half if the switch is enabled and turned on.
(14) Configurable max reverse power to half.
(15) Enhanced regen brake function. Novel ABS technique provides powerful and smooth
regen.
(16) Configurable 12V brake signal input, instead of motor temperature sensor.
(17) Optional joystick throttle. Single 0-5V signal for both forwarding and reversing.
(18) Thermal overload detection and protection to safeguard the motor from over temperature
(designed using Silicon temperature sensors KTY83-122).
(19) 3 hall position sensor inputs. Open collector, pull up provided.
(20) Optional supply voltage 8V-30V.
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 Ebike Brushless DC Motor Controller User’s Manual V 3.3
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2.2 Features
•Specially designed for electric bicycle and scooter.
•Intelligence with powerful microprocessor.
•Synchronous rectification, ultra low drop, fast PWM to achieve very high efficiency.
•Electronic reversing.
•Voltage monitoring on 3 motor phases, bus, and power supply.
•Voltage monitoring on voltage source 12V and 5V.
•Current sense on all 3 motor phases.
•Current control loop.
•Hardware over current protection.
•Hardware over voltage protection.
•Support torque mode, speed mode, and balanced mode operation.
•Configurable limit for motor current and battery current.
•Battery current limiting available, doesn’t affect taking off performance.
•More startup current ,can get more startup speed.
•Low EMC.
•LED fault code.
•Battery protection: current cutback, warning and shutdown at configurable high and low
battery voltage.
•Rugged aluminum housing for maximum heat dissipation and harsh environment.
•Rugged high current terminals, and rugged aviation connectors for small signal.
•Thermal protection: current cut back, warning and shutdown on high temperature.
•Configurable 60 degree or 120 degree hall position sensors.
•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 = mechanical RPM * motor pole pairs).
•Brake switch is used to start regen.
•0-5V brake signal is used to command regen current.
•Support three modes of regenerative braking: brake switch regen, release throttle regen,
0-5V analog signal variable regen.
•Configurable high pedal protection: Disable operation if power up with high throttle.
•Current multiplication: Take less current from battery, output more current to motor.
•Easy installation: 3-wire potentiometer will work.
•Current meter output.
•Standard PC/Laptop computer to do programming. No special tools needed.
•User program provided. Easy to use. No cost to customers.
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.

Kelly Ebike Brushless DC Motor Controller User’s Manual V 3.3
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•Supply Current, PWR, 150mA.
•Configurable battery voltage range, B+. Max operating range: 18V to 1.25*Nominal.
•Standard Throttle Input: 0-5 Volts(3-wire resistive pot), 1-4 Volts(hall active throttle).
•Analog Brake and Throttle Input: 0-5 Volts. Producing 0-5V signal with 3-wire pot.
•Full Power Operating Temperature Range: 0ﹾＣto 50ﹾＣ(controller case temperature).
•Operating Temperature Range: -30ﹾＣto 90ﹾＣ,100ﹾＣshutdown(controller case temperature).
•Peak Phase Current, 30 seconds: 100-350A, depending on the model.
•Continuous Phase Current Limit: 50A-150A, depending on the model.
•Maximum Battery Current: Configurable
2.4 Models
The naming regulations of the Kelly KEB motor controller model:

Kelly Ebike Brushless DC Motor Controller User’s Manual V 3.3
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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 holes’dimensions are shown in Figure 1.
Height: 62 millimeters
Figure 1: mounting holes’dimensions (dimensions in millimeters)

Kelly Ebike Brushless DC Motor Controller User’s Manual V 3.3
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3.2 Connections
3.2.1 Front Panel of KEB Motor Controller:
Five metal bars and a 14pin rugged connector are provided for connecting to the battery,
motor and control signals in the front of the controller shown as Figure 2.
Figure 2: Front panel of KEB motor controller
B+: battery positive
B-: battery negative
A: Output U/1/A phase
B: Output V/2/B phase
C: Output W/3/C phase
Figure 3: The connecting diagram of J2
J2 Pin Definition
1- PWR: Controller power supply
2- RTN: Signal return, or power supply ground
3- RTN: Signal return
4- 12V high-level brake and 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.

Kelly Ebike Brushless DC Motor Controller User’s Manual V 3.3
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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 pins are internally connected. RTN is internally connected to B-.
2. Switch to ground is active. Open switch is inactive
Caution: Make sure all connections are correct before applying power. Otherwise it may
damage the controller! Please securely wire B- before applying power. It's preferred to place
contactor or breaker on B+. Please place precharge resistor on any breaker! It can cause
damage without it!!!

Kelly Ebike Brushless DC Motor Controller User’s Manual V 3.3
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3.2.2 Standard Wiring of KEB Motor Controller
Figure 4: KEB controller standard wiring
(Battery voltage can be used for controller supply)

Kelly Ebike Brushless DC Motor Controller User’s Manual V 3.3
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3.2.3 Communication Port
A RS232 port of controller is provided to communicate with host computer for calibration and
configuration.
Figure 5: standard RS232 interface
3.3 Installation Check List
Before operating the vehicle, complete the following checkout procedures. 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 both the PWR switch and the brake are off
• Use well-insulated tools.
•Make sure the wire is connected correctly
•Turn the PWR switch on. The LED should blink, then keep 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 restarting.
•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 operate. 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 have smooth
acceleration and good top speed.

Kelly Ebike Brushless DC Motor Controller User’s Manual V 3.3
Page 11
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 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.
•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.
•Remove any dirt or corrosion from the bus bar area. The controller should be wiped down
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 or USB port.
•Use straight RS232 cable or Kelly Standard USB To RS232 Converter to connect the 9pin
connector on face panel to a host computer Provide 18V to 90V to PWR. Wire power
supply ground to any RTN pin.
•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.
Download and setup the configuration software：
http://www.kellycontroller.com/support.php
Caution:
•Prohibit connecting controller's configuration software when the motor is running.
•Configuration software will be regularly updated and published on the website. Please
regularly uninstall the previous configuration software from your computer, download
and install the new one.
•As for "Hall Sensor Type" in GUI, please do not click "Auto-Check", which had been
deleted from the new version of configuration software.

Kelly Ebike Brushless DC Motor Controller User’s Manual V 3.3
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Table 1: LED CODES
LED Code
Explanation
Solution
Green Off
No power or not
operating
1. Check if all wires are correct.
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. Supply voltage is too low or battery is too high.
3. The controller is damaged. Please contact Kelly
for warrantee.
Red LED Codes
LED Code
Explanation
Solution
1,2
¤¤¤
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.
3. Please note there could be 2% error with
Overvoltage setting.
1,3
¤¤¤¤
Low voltage error
1. The controller will attempt to clear the fault
code automatically after 5 second if battery
voltage returns to normal.
2. Check the battery voltage.
3. Charge battery if necessary.
1,4
¤¤¤¤¤
Over temperature
warning
1. The controller temperature is over 90ºC. The
controller will cut back current in the case. Stop
or reduce output to ensure the temperature fall.
2. Improve heat sink or airflow.
2,1
¤¤ ¤
Motor fails to start
1. Motor hasn’t reached 25 electrical RPM after 2
seconds from starting. Most likely the hall or
phase wiring problem.
2,2
¤¤ ¤¤
Internal voltage
fault
1. Check if the B+ and PWR voltage are correct,
refer to B- or RTN. Could be PWR voltage low.
2. Please check load on 5V supply. Could be high
load on 5V. Incorrect pot wiring can load it
heavily.
3. The controller is damaged. Please contact
Kelly for warrantee.
2,3
¤¤ ¤¤¤
Over temperature
1. When controller’s temperature is over 100℃. it
will stop driving in order to protect itself.
2. Stop driving and wait for temperature fall. The
controller will restart if temperature drops below
80℃.

Kelly Ebike Brushless DC Motor Controller User’s Manual V 3.3
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2,4
¤¤ ¤¤¤¤
Throttle error at
power up
1. The throttle signal is higher than configured
dead zone at power-on
2. The fault will disappear if restarts or releases
throttle.
3. Configure throttle type as "Hall Active" throttle if
you use that type.
3,1
¤¤¤ ¤
Frequent reset
1. The controller will stop driving after detecting
too many resets.
2. Mostly because of B- or return wiring. Use the
heavier and cleaner return wires. For dual
controllers, bond B- of both controllers together
with heavy cable or copper strip.
3. Could be over current protection. May set max
current lower.
4. Restarting will clear the error.
5. Please contact Kelly if it happens repeatedly.
3,2
¤¤¤ ¤¤
Internal reset
Reset caused by over current, high battery voltage
or low supply voltage. It is normal if occurs
occasionally.
3,3
¤¤¤ ¤¤¤
Throttle short or
open circuit when
using 1-4v hall
sensor throttle
1. Check whether the throttle is short or open
circuit.
2. When the throttle is normal, restart will clear the
error.
3,4
¤¤¤ ¤¤¤¤
Throttle isn’t zero
when try to
change direction
The controller won’t change drive direction if
throttle isn’t zero. Also it won’t change direction at
high speed. The controller will wait throttle and
speed close to zero before changing direction.
4,1
¤¤¤¤ ¤
Over voltage at
startup or
regeneration
The controller won’t drive motor if detects
overvoltage at power up. It will cut back regen
current or stop regen at overvoltage. You may set
max voltage threshold with GUI.
4, 2
¤¤¤¤ ¤¤
Hall sensor signal
error
1. Most likely caused by incorrect hall wiring (to
wrong pin or loose wire).
2. Intermittent or damaged hall sensor.
3. Double check hall angle setting, 60 degree or
120 degree.
4, 3
¤¤¤¤ ¤¤¤
Motor over
temperature
1. The motor temperature is higher than configured
max temperature. Controller will shut down and
wait for motor temperature dropping.
2. Change the temperature setting with
configuration program.
4, 4
¤¤¤¤
¤¤¤¤
Motor locked rotor
When in locked rotor condition, the max output
phase current of the motor will be limited to 90% of
previous current. Once the locked rotor disappear,

Kelly Ebike Brushless DC Motor Controller User’s Manual V 3.3
Page 14
the fault codes will disappear and the max output
phase current will return to normal.
The Red LED flashes once at power on, then keeps off 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.
Contact Us:
Kelly Controls, LLC
Home Page:
http://www.KellyController.com
E-mail:
[e-mail]
Phone:
[phone] 5092