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Summary of Contents for Kelly KBS24051
- Page 1 Kelly KBS Brushle ss Motor Controller User’ s Manual V 4.1 Kelly KBS Brushless Motor Controller User’s Manual Devices Supported: KBS24051 KBS48051 KBS24051E KBS48051E KBS24101 KBS48101 KBS24121 KBS48121 KBS36051 KBS72051 KBS36101 KBS72101 KBS72121 Rev.4.1 Dec. 2011...
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Page 2: Table Of Contents
Kelly KBS Brushle ss Motor Controller User’ s Manual V 4.1 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 ....................... -
Page 3: Chapter 1 Introduction
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, LLC. 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. -
Page 4: Chapter 2 Features And Specifications
Kelly KBS Brushle ss Motor Controller User’ s Manual V 4.1 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 Brushle ss Motor Controller User’ s Manual V 4.1 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
Kelly KBS Brushle ss Motor Controller User’ s Manual V 4.1 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. -
Page 7: Chapter 3 Wiring And Installation
Kelly KBS Brushle ss Motor Controller User’ s Manual V 4.1 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. -
Page 8: Connections
Kelly KBS Brushle ss Motor Controller User’ s Manual V 4.1 3.2 Connections 3.2.1 Pin definition of KBS Controller waterproof connector Figure 2: 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. - Page 9 (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: •...
- Page 10 Kelly KBS Brushle ss Motor Controller User’ s Manual V 4.1 3.2.2 Wiring of KBS Controller 3.2.2.1 Standard wiring of KBS controller Figure 3: KBS controller standard wiring (Battery voltage can be used for controller supply)
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Page 11: Installation Check List
V 4.1 3.2.2.2 Optional wiring of KBS controller The output signal of the pin is for Kelly current meter. Figure 4: wiring of current meter pin The 12V input signal of the pin supplies the second braking function of the controller. - Page 12 Kelly KBS Brushle ss Motor Controller User’ s Manual V 4.1 • 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.
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Page 13: Chapter 4 Programmable Parameters
Kelly KBS Brushle ss Motor Controller User’ s Manual V 4.1 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 14: Step 2
Kelly KBS Brushle ss Motor Controller User’ s Manual V 4.1 Value range: 60%-100% Functional description: Set throttle effective endi ng 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). -
Page 15: Step 3
Kelly KBS Brushle ss Motor Controller User’ s Manual V 4.1 18~60 18~60 18~90 18~90 120V 18~136 18~136 144V 18~180 18~180 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 16: Step 4
Kelly KBS Brushle ss Motor Controller User’ s Manual V 4.1 Configuration Pin Status Output Current Boost Economy J2-6 (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 17: Step 5
Kelly KBS Brushle ss Motor Controller User’ s Manual V 4.1 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 18: 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 19 Kelly KBS Brushle ss Motor Controller User’ s Manual V 4.1 Table 1: LED CODES Green LED Codes LED Code Explanation Solution Green Off No power or 1. Check if all wires are correct. switched off 2. Check fuse and power supply.
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Page 20: Contact Us
Kelly KBS Brushle ss Motor Controller User’ s Manual V 4.1 ¤ ¤ ¤ ¤ Frequent reset May be caused by over-voltage, bad motor intermittent earthing problem, bad wiring, etc. ¤ ¤ ¤ ¤ ¤ Internal reset May be caused by some transient fault condition like a temporary over-current, momentarily high or low battery voltage.