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Summary of Contents for Kelly KBS-X
- Page 1 Kelly KBS-X Brushless Motor Controller User’s Manual V 4.2 Kelly KBS-X Brushless Motor Controller User’s Manual Devices Supported: KBS24051X KBS24101X KBS24121X KBS36051X KBS36101X KBS48051X KBS48101X KBS48121X KBS72051X KBS72101X KBS72121X Rev.4.2 June. 2022...
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Page 2: Table Of Contents
Kelly KBS-X Brushless Motor Controller User’s Manual V 4.2 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-X Brushless Motor Controller User’s Manual V 4.2 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-X Brushless Motor Controller User’s Manual V 4.2 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
Kelly KBS-X Brushless Motor Controller User’s Manual V 4.2 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-X Brushless Motor Controller User’s Manual V 4.2 Kelly KBS-X Brushless Motor Controller Model 30 seconds Continuous Voltage(Volt) Current(Amp) Current(Amp) KBS24051X 12-24 KBS24101X 12-24 KBS24121X 12-24 KBS36051X 24-36 KBS36101X 24-36 KBS48051X 24-48 KBS48101X 24-48 KBS48121X 24-48 KBS72051X 24-72 KBS72101X... - Page 8 Kelly KBS-X Brushless Motor Controller User’s Manual V 4.2 KBS -X mounting holes‟ dimensions (dimensions in millimeters) Figure 1:...
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Page 9: Connections
Kelly KBS-X Brushless Motor Controller User’s Manual V 4.2 3.2 Connections 3.2.1 Pin definition of KBS-X Controller waterproof connector Figure 2: 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 10 (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 11 Kelly KBS-X Brushless Motor Controller User’s Manual V 4.2 3.2.2 Wiring of KBS-X Controller 3.2.2.1 Standard wiring of KBS-Xcontroller Figure 3: KBS-X controller standard wiring (Battery voltage can be used for controller supply)
- Page 12 Kelly KBS-X Brushless Motor Controller User’s Manual V 4.2 Figure 4:KBS-X F-N-R control wiring diagram...
- Page 13 Figure 6: Wiring of brake switch(12V): 12V is provided by external source. Figure 7: Wiring of brake switch(12V): 12V is provided by KBS-X controller on pin11 Figure 8: Wiring of motor temperature sensor: pin1-Brk2 can be used as motor temperature...
- Page 14 Kelly KBS-X Brushless Motor Controller User’s Manual V 4.2 3.2.3 Communication Port A RS232 port is provided to communicate with host computer for calibration and configuration. Figure 9: RS232 Interface on KBS controller Figure 10：SM-4P connector for communication interface on KBS-X controller...
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Page 15: Installation Check List
Kelly KBS-X Brushless Motor Controller User’s Manual V 4.2 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 16: Chapter 4 Programmable Parameters
Kelly KBS-X Brushless Motor Controller User’s Manual V 4.2 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 17: Step 2
Kelly KBS-X Brushless Motor Controller User’s Manual V 4.2 (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). -
Page 18: Step 3
Kelly KBS-X Brushless Motor Controller User’s Manual V 4.2 Controller Rated voltage Under Voltage Range (V) Over Voltage Range(V) 8~30 8~30 18~45 18~45 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 19: Step 4
Kelly KBS-X Brushless Motor Controller User’s Manual V 4.2 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 20: Step 5
Kelly KBS-X Brushless Motor Controller User’s Manual V 4.2 Functional description: Set the max allowed regen current in brake switch regen mode. 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. -
Page 21: 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 22 Normal operation Green On 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 Solution Over voltage error ¤...
- Page 23 Kelly KBS-X Brushless Motor Controller User’s Manual V 4.2 potentiometers or incorrect wiring. 3. Controller is damaged. Contact Kelly about a warranty repair. Over temperature ¤¤ ¤¤¤ The controller temperature has exceeded 100℃. The controller will be stopped but will restart when temperature falls below 80℃.
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Page 24: Contact Us
Kelly KBS-X Brushless Motor Controller User’s Manual V 4.2 Contact Us: Kelly Controls Home Page: http://www.KellyController.com E-mail: sales@kelly-controls.com Phone: (01) 224 637 5092...