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Summary of Contents for Kelly KBS48181E
- Page 1 Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2 Kelly KBS-E Brushless Motor Controller User’s Manual Devices Supported: KBS48151E KBS72151E KBS48181E KBS72181E KBS48221E KBS72221E Rev.1.2 Dec.2016...
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Page 2: Table Of Contents
Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2 Contents Chapter 1 Introduction ....................1.1 Overview..........................2 Chapter 2 Features and Specifications ..............2.1 General functions....................... 3 2.2 Features..........................4 2.3 Specifications........................5 2.4 Name Regulation........................5 Chapter 3 Wiring and Installation ................ -
Page 3: Chapter 1 Introduction
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. -
Page 4: Chapter 2 Features And Specifications
Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2 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”... -
Page 5: Features
Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2 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. -
Page 6: Specifications
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... -
Page 7: Chapter 3 Wiring And Installation
Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2 Kelly KBS-E Brushless Motor Controller Model 10 seconds Continuous Voltage(Volt) Current(Amp) Current(Amp) KBS48151E 24-48 KBS48181E 24-48 KBS48221E 24-48 KBS72151E 24-72 KBS72181E 24-72 KBS72221E 24-72 1.48V model: range of the max operating voltage is 18-60V. - Page 8 Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2 Height: 41 millimeters mounting holes’ dimensions (dimensions in millimeters) Figure 1:KBSXX151E...
- Page 9 Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2 Height: 51.5 millimeters mounting holes’ dimensions (dimensions in millimeters) Figure 2:KBSXX181E...
- Page 10 Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2 Height: 58.5 millimeters mounting holes’ dimensions (dimensions in millimeters) Figure 3:KBSXX221E...
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Page 11: Connections
Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2 3.2 Connections 3.2.1 Pin definition of KBS-E Controller waterproof connector Figure 4: 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. - Page 12 (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: •...
- Page 13 Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2 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)
- Page 14 Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2 Figure 6:KBS-E F-N-R control wiring diagram...
- Page 15 V 1.2 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.
- Page 16 Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2 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...
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Page 17: Installation Check List
Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2 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. -
Page 18: Chapter 4 Programmable Parameters
Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2 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. -
Page 19: Step 2
Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2 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%. -
Page 20: Step 3
Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2 Controller Rated voltage Under Voltage Range (V) Over Voltage Range(V) 18~60 18~60 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. -
Page 21: Step 4
Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2 Configuration Pin Status Output Current Boost Economy BRK_AN(2) (Max Current：I_max) Disable Disable 0~I_max 0~(I_max * 50%) Disable Enable 0~I_max I_max Enable Disable 0~(I_max * 60%) Figure 4.3 Note: Boost Function, Economy Function and Half Current In Reverse can not be used at the same time. -
Page 22: Step 5
Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2 Suggestion: Set according to the practical situation, factory default is 20%. (5)Max Regen Current Value range: 20%~100% Functional description: Max regen current with max signal from brake sensor. Suggestion: Set according to the practical situation, factory default is 100%. -
Page 23: Chapter 5 Maintenance
• Use a straight through RS232 cable or USB converter provided by Kelly to connect to a host computer. Provide >+18V to PWR（for a 24V controller, provide >+8V）. Wire power supply return(supply negative) to any RTN pin. -
Page 24: Table 1: Led Codes
That’s great! You got solution! Green & Red are both 1. Software needs upgrading. 2. Supply voltage too low or battery too high 3. The controller is damaged. Contact Kelly about a warranty repair. Red LED Codes LED Code Explanation... - Page 25 B- or RTN. 2. There may be excessive load on the +5V supply caused by too low a value of Regen or throttle potentiometers or incorrect wiring. 3. Controller is damaged. Contact Kelly about a warranty repair. Over temperature ¤¤...
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Page 26: Contact Us
Kelly KBS-E Brushless Motor Controller User’s Manual V 1.2 Contact Us: Kelly Controls Home Page: http://www.KellyController.com E-mail: sales@kelly-controls.com Phone: (01) 224 637 5092...
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