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Kelly KHB High Power Brushless Motor Controller User's Manual
Kelly KHB High Power Brushless Motor Controller
KHB72601
KHB12151
KHB12601
KHB14201
User's Manual
Devices Supported:
KHB72701
KHB12201
KHB12801
KHB14301
KHB72101
KHB12251
KHB14401
KHB12301
KHB12401
KHB14601
V 3.3
Rev.3.3
Feb. 2025
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Summary of Contents for Kelly KHB72601
- Page 1 Kelly KHB High Power Brushless Motor Controller User’s Manual V 3.3 Kelly KHB High Power Brushless Motor Controller User’s Manual Devices Supported: KHB72601 KHB72701 KHB72101 KHB12151 KHB12201 KHB12251 KHB12301 KHB12401 KHB12601 KHB12801 KHB14201 KHB14301 KHB14401 KHB14601 Rev.3.3 Feb. 2025...
- Page 2 Kelly KHB High Power Brushless Motor Controller User’s Manual V 3.2 Contents Kelly KHB High Power Brushless Motor Controller ..........0 User’s Manual ...................... 0 Contents ......................1 Chapter 1 ....................... 2 1.1 Overview........................ 2 Chapter 2 Features and Specifications ............3 2.1 General functions ....................
- Page 3 1 Introduction 1.1 Overview The manual introduces Kelly high power BLDC motor controllers’ features, installation and 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.
- Page 4 Kelly KHB High Power Brushless Motor Controller User’s Manual V 3.2 Chapter 2 Features and Specifications 2.1 General functions (1) Extended fault detection and protection. LED flashing for fault code 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.
- Page 5 Kelly KHB High Power Brushless Motor Controller User’s Manual V 3.2 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!).
- Page 6 Kelly KHB High Power Brushless Motor Controller User’s Manual V 3.2 2.3 Specifications •Frequency of Operation: 16.6kHz. •Standby Battery Current: < 0.5mA. •5V Sensor Supply Current: 40mA. •Controller supply voltage range, PWR, 10 to 30V (24V preferred) •Configurable battery voltage range, B+. Max operating range: 18V to 136V for controller rated equal 120V.
- Page 7 Kelly KHB High Power Brushless Motor Controller User’s Manual V 3.2 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.
- Page 8 Kelly KHB High Power Brushless Motor Controller User’s Manual V 3.2 3.2 Connections 3.2.1 Front Panel and back panel of KHB Motor Controller: Five metal bars in front panel and two plugs (J1, J2) in back panel are provided for connecting to the battery, motor and control signals shown as Figure 5, 6 and 9.
- Page 9 EMC. Recirculation diodes are provided in the controller to PWR for alarm and Contactor coil driver. 3. Kelly Ampmeter positive connect to 5V power supply of controller, negative to J1-2. 4. Switch to ground is active. Open switch is inactive.
- Page 10 Kelly KHB High Power Brushless Motor Controller User’s Manual V 3.2 3.2.2 Wiring of KHB Motor Controller Figure 11: Standard Wiring for KHB Controllers (12V or 24V battery supply is required) Page 9...
- Page 11 Kelly KHB High Power Brushless Motor Controller User’s Manual V 3.2 3.2.3 Communication Port A RS232 port is provided to communicate with host computer for calibration and configuration. Figure 12: standard RS232 Interface 3.4 Installation Check List Before operating the vehicle, complete the following checkout procedures. Use LED code as a reference.
- Page 12 You can configure the controller with a host computer through RS232 or USB port. • Use straight through RS232 cable or USB converter provided by Kelly to connect the D9 connector to a host computer. Provide >10V (either J2 pin1 or J1 pin1) to PWR. Wire power supply return to any RTN pin.
- Page 13 Kelly KHB High Power Brushless Motor Controller User’s Manual V 3.2 Table 1: LED CODES Green LED Codes LED Code Explanation Solution No power or not Green Off 1. Check if all wires are correct. operating 2. Check fuse and power supply.
- Page 14 Kelly KHB High Power Brushless Motor Controller User’s Manual V 3.2 Controller stops driving in the case. 2. Stop driving and wait for temperature fall. The controller will restart if temperature drops below 80 . ℃ Throttle error at ¤¤...
- Page 15 Kelly KHB High Power Brushless Motor Controller User’s Manual V 3.2 Table 2: KHB Controller CAN Commands List Version 1.1 You should specify when sending: ID:Our default ID is 0x6B, so only the data frame with ID 107 can be received by our controller.
- Page 16 Kelly KHB High Power Brushless Motor Controller User’s Manual V 3.2 Command CCP_FLASH_READ Length data[0] 0xF2 data[1] CAL_BRAKE_DEAD_ZONE_LOW data[2] Controller response Length data[0] Brake_Dead_Zone_Low Desccription: Getting controller’s Brake low-end dead zone. CAL_BRAKE_DEAD_ZONE_LOW constant is defined as 5. Command CCP_FLASH_READ Length...
- Page 17 Kelly KHB High Power Brushless Motor Controller User’s Manual V 3.2 Controller response Length data[0] Ia A/D data[1] Ib A/D data[2] Ic A/D data[3] Va A/D data[4] Vb A/D data[5] Vc A/D Description: Data batch reading. 1) For Va, Vb, Vc, A/D value and voltage mapping relation is: V = Vad / 1.84.
- Page 18 Kelly KHB High Power Brushless Motor Controller User’s Manual V 3.2 Length data[0] 0x42 data[0] COM_READING Controller response Length data[0] Current throttle switch status Description: Getting Throttle switch status, 1 – active, 0 – inactive. COM_READING constant is defined as 0.
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