Kelly KBL48101, KBL24151, KBL24201, KBL24301, KBL48151 User Manual

Kelly

Kelly KBL

KBL

KBL Brushless

Brushless

Brushless Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Manual V

V

V 3.3

3.3

Kelly

Kelly KBL

KBL

KBL Brushless

Brushless

Brushless Motor

Motor

Controller

Controller User

User

’

s

s Manual

Manual

Devices

Devices Supported:

Supported:

KBL24101

KBL24101 KBL36101

KBL36101

KBL09151

KBL24151

KBL24151 KBL36151

KBL36151

KBL09201

KBL24201

KBL24201 KBL36201

KBL36201

KBL09251

KBL24301

KBL24301 KBL36301

KBL36301

KBL09401B

KBL48101

KBL48101 KBL72101

KBL72101

KBL48151

KBL48151 KBL72151

KBL72151

KBL48201

KBL48201 KBL72201

KBL72201

KBL48301

KBL48301 KBL72301

KBL72301

KBL48401B

KBL48401B KBL72401B

KBL72401B

KBL48501B

KBL48501B KBL72501B

KBL72501B

Rev. 3.3

Aug. 20 11

Kelly

Kelly KBL

KBL

KBL Brushless

Brushless

Brushless Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Manual V

V

V 3.3

3.3

Page 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

.................................................................................................

4

2.4 Naming Regulations

......................................................................................

5

Chapter 3 Wiring and Installation

..........................................................................

6

3.1 Mounting the Controller

................................................................................

6

3.2 Connections

...................................................................................................

7

3.3 Installation Check List

................................................................................

1 2

Chapter 4 Maintenance

........................................................................................

13

4.1 Cleaning

........................................................................................................

13

4.2 Configuration

................................................................................................

13

Table 1: LED CODES

...............................................................................................

14

Green LED Codes

.............................................................................................

14

Red LED Codes

.................................................................................................

14

Table 2: KBL Controller CAN Commands List

.....................................................

16

Contact Us:

................................................................................................................

1 9

Kelly

Kelly KBL

KBL

KBL Brushless

Brushless

Brushless Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

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Manual

Manual V

V

V 3.3

3.3

Page 2

Chapter

Chapter 1

1

1 Introduction

Introduction

1.1

1.1 Overview

Overview

Th is manual introduce s the Kelly BLDC motor controller s’features, their installation and their maintenance. R ead the manual carefully and thoroughly before us ing 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 qui et control s for golf cart s , go-cart s , electric motorcycle s , forklift s , hybrid vehicle s, electric vehicle s and electric boat s , as well as industr ial motor speed or torque control. It uses high power MOSFET’s and , PWM to achieve efficienc ies of up to 9 9 % in most cases.

A

p owerful microprocessor brings in comprehensive and precise control to the controllers. It also allow s users to adjust parameters, conduct tests, and obtain diagnostic information quickly and easily.

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KBL

KBL Brushless

Brushless

Brushless Motor

Motor

Motor Controller

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Page 3

Chapter

Chapter 2

2

2 Features

Features

Features and

and

and Specifications

Specifications

2.1

2.1 General

General

General functions

functions

(1) Extended fault detection and protection. The LED flashing pattern indicates the fault

sources .

(2) Monitoring battery voltage . It will s top driving if the battery voltage is too high and i t will

progressively cut back motor drive power as battery voltage drops until it cuts out

altogether at the preset “ Low Battery Voltage ” setting. (3) Built-in current loop and over current protection. (4) Configurable m otor temperature protection range. (5) Current cutback at low temperature and high temperature to protect battery and controller.

The current begins to ramp down at 90 ﹾ Ｃ case temperature , shut ting down at 100 ﹾ Ｃ . (6) The controller keeps monitoring battery recharging voltage during regen erative braking,

progressively cutting back current as battery voltage rises then cutting off regen altogether

when voltage goes too high. (7) Maximum reverse speed is configurable to half of max forward speed . (8) Configurable and programmable with a host computer though RS232 or USB. Provide free

GUI which can run on Windows XP/2000, Windows 7 and Vista(recommend using Kelly

Standard USB

To

RS232 Converter). (9) Provision of a +5 volt output to supply various kinds of sensors, including Hall effect type. (10) 3 switch inputs which are activated by connection to Ground . D efault to throttle switch,

brake switch and revers ing switch. Clos ing to ground is to activate. (11) 3 analog 0-5V inputs that d efault to throttle input, brake input and motor temperature input . (12) P ulsed r everse alarm output. (13) Main c ontactor driver. Cut ting off the power if any fault is detected . (14)Current meter can display both drive and regen current. Save shunt! (15)Configurable b oost switch . Enables the maximum output power achievable if the switch is

turned on. (16)Configurable economy switch . Limit s the maximum current to half if the switch is turned on. (17) Maximum reverse power is configurable to half power. (18)Enhanced regen brake function.Anovel ABS technique provides powerful and smooth regen. (19)Configurable 12V brake signal input, instead of motor temperature sensor. (20)Optional joystick throttle.Abi-symmetrical 0-5V signal for both forward ing and reversing (21) Configurable motor over-temperature detection and protection with the recommended

thermistor KTY83-122. (22)3 hall position sensor inputs . Open collector, pull up provided. (23) Optional CAN bus. (24)Optional supply voltage 8- 3

0V.

Caution!

Caution! Regeneration has braking effect but does not replace the function of a mechanical

brake. A m echanical brake is required to stop your vehicle. Regen IS NOT a safety feature! Controller may stop regen , without warning, to protect itself or the battery ( it won’t protect you!).

Kelly

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KBL Brushless

Brushless

Brushless Motor

Motor

Motor Controller

Controller

Controller User

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Page 4

2.2

2.2 Features

Features

1) Intelligence with powerful microprocessor.

2) Synchrono u s rectification, ultra low drop and fast PWM to achieve very high efficiency.

3) Electronic reversing.

4) Voltage monitoring on 3 motor phases, bus, and power supply .

5) Voltage monitoring on voltage source 12V and

5V

.

6) Current sense on all 3 motor phases .

7) Current control loop .

8) Hardware over current protection .

9) Hardware over voltage protection .

10) Support torque mode, speed mode, and balanced mode operation .

11) Configurable limit for motor current and battery current .

12) Low EMC.

13) LED fault code.

14) Battery protection: current cutback, warning and shutdown at configurable high and low

battery voltage.

15) Rugged aluminum housing for maximum heat dissipation and harsh environment .

16) Rugged high current terminals, and rugged aviation connectors for small signal.

17) Thermal protection: current cut back, warning and shutdown at high temperature .

18) Configurable 60 degree or 120 degree hall position sensor s .

19) S upport motors with any number of poles . Up to 4 0 , 000 electric RPM standard . Optional

high speed 70,000 ERPM , and ultra high speed 100,000 ERPM. (Electric RPM = mechanical RPM * motor pole pairs) .

20) Support three modes of regenerative braking: brake switch regen, release throttle regen,

0-5V analog signal variable regen.

21) Configurable high pedal protection: Disable operation if power up with high throttle.

22) Current multiplication: Take less current from battery, output more current to motor .

23) Easy installation: 3 wire potentiometer can work .

24) Remo t e fault code LED driver .

25) Current meter output .

26) Standard PC/Laptop computer is used to do programming. No special tools needed.

27) User program provided. Easy to use. No cost to customers.

2.3

2.3 Specifications

Specifications

•

Frequency of Operation: 16.6kHz.

•

Standby Battery Current: < 0.5 mA.

•

5V Sensor Supply Current: 40mA.

•

Controller supply voltage range, PWR, 8V to 30V for KBL 24V controllers. 18V to 90V for KBL controllers rated equal or lower than 72V . 18V to 120V for 96V controllers.

•

Configurable battery voltage range , B+ . Max operating range : 18V to 1.25 * Nominal Voltage for

Kelly

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Brushless

Brushless Motor

Motor

Motor Controller

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controller rated equal or higher than 36V . 8V to 30V for controller rated equal 24V.

•

Standard Throttle Input: 0-5 Volts(3-wire resistive pot), 1-4 Volts(hall active throttle).

•

Analog Brake and Throttle Input: 0-5 Volts. P roduc ing 0-5V signal with 3- wire pot .

•

Reverse Alarm, Main Contactor Coil Driver, Meter.

• Full Power Operating Temperature Range: 0

ﹾ Ｃ

to 50

ﹾ Ｃ

(controller case temperature).

• Operating T emperature Range:-30 ﹾ Ｃ to 90 ﹾ Ｃ ,100 ﹾ Ｃ shutdown(controller case temperature).

• Motor Current Limit, 1 minute: 100 -5 00A, depending on the model.

• Motor Current Limit, continuous: 50A -250 A, depending on the model.

• Max Battery Current : Configurable .

2.4

2.4 Na

Na

Na m

m

m ing

ing

ing Regulation

Regulation

Regulation s

s

The naming regulations of Kelly BLDC motor controller s :

Kelly

Kelly KBL

KBL

KBL Brushless

Brushless

Brushless Motor

Motor

Motor Controller

Controller

Controller User

User

’

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Manual

Manual V

V

V 3.3

3.3

Page 6

Chapter

Chapter 3

3

3 Wiring

Wiring

Wiring and

and

and Installation

Installation

3.1

3.1 Mounting

Mounting

Mounting the

the

the Controller

Controller

The controller can be oriented in any position which should be as clean and dry as possible , if necessary , shielded 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 or six screws. Applying silicon g rease or some other thermal conductive material to contact surface will enhance thermal performance.

Proper heat sink ing and airflow are vital to achieve the full power capability of the

controller.

The case outline and mounting hole s’dimensions are shown in Figure 1.

Height: 62 millimeters

Figure

Figure 1:

1:

1: KBL mounting hole s

’

dimensions ( dimensions in millimeter s)

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KBL

KBL Brushless

Brushless

Brushless Motor

Motor

Motor Controller

Controller

Controller User

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Height: 62 millimeters

Figure

Figure 2

2

2 :

:

: KBL-B mounting hole s

’

dimensions ( dimensions in millimeter s)

3.2

3.2 Connections

Connections

3.2.1

3.2.1 Front

Front

Front Panel

Panel

Panel of

of

of BLDC

BLDC

BLDC Motor

Motor

Motor Controller:

Controller:

Five metal bars and two plugs (J1, J2) are provided for conne ct ing to the battery, motor and

control signals in the front of the controller shown as Figure 3.

Figure

Figure 3:

3:

3: Front panel of BLDC motor controller

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Kelly KBL

KBL

KBL Brushless

Brushless

Brushless Motor

Motor

Motor Controller

Controller

Controller User

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B+:

B+: battery

battery

battery positive

positive

B-:

B-: battery

battery

battery negative

negative

A:

A: Output

Output

Output U/1/A

U/1/A

U/1/A phase

phase

B:

B: Output

Output

Output V/2/B

V/2/B

V/2/B phase

phase

C:

C: Output

Output

Output W/3/C

W/3/C

W/3/C phase

phase

Figure

Figure 4:

4:

4: The connecting diagram of J1

J1

J1 and J2

J2

J1

J1 Pin

Pin Definition

Definition

1-

1- PWR

PWR

PWR :

:

: Control

Control

Control ler

ler

ler power

power

power supply

supply

supply (output).

(output).

(output). The

The

The pin

pin is

is

is Red

Red

LED

LED for

for

for S/N

S/N

S/N less

less

less :08XXXXXX.

:08XXXXXX.

2-

2- Current

Current

Current meter.

meter.

meter. <200mA

<200mA

3-

3- Main

Main

Main contactor

contactor

contactor driver.

driver.

driver. <

<

< 2

2

2 A

A

4-

4- Alarm:

Alarm:

Alarm: To

To

To drive

drive

drive reverse

reverse

reverse beeper.

beeper.

beeper. <200mA

<200mA

5-

5- RTN:

RTN:

RTN: Signal

Signal

Signal return

return

6-

6- Green

Green

Green LED:

LED:

LED: Running

Running

Running indication

indication

7-

7- RTN:

RTN:

RTN: Signal

Signal

Signal return

return

8-

8- RS232

RS232

RS232 receiv

receiv

receiv er

er

9-

9- RS232

RS232

RS232 transmitt

transmitt

transmitt er

er

10-

10- CAN

CAN

CAN bus

bus

bus high

high

11-

11- CAN

CAN

CAN bus

bus

bus low

low

12-

12- Reserved

Reserved

13-

13- RTN:

RTN:

RTN: Signal

Signal

Signal r

r

r eturn,

eturn,

eturn, or

or

or power

power

power supply

supply

supply return

return

14-

14- Red

Red

Red LED:

LED:

LED: F

F

F ault

ault

ault code

code

code .The

.The

.The pin

pin is

is

is PWR

PWR

PWR for

for

for S/N

S/N

S/N less

less

less :08XXXXXX.

:08XXXXXX.

J2

J2 Pin

Pin Definition

Definition

1-

1- PWR

PWR

PWR :

:

: Control

Control

Control ler

ler

ler power

power

power supply

supply

supply (input)

(input)

2-

2- RTN:

RTN:

RTN: Signal

Signal

Signal r

r

r eturn,

eturn,

eturn, or

or

or power

power

power supply

supply

supply return

return

3-

3- RTN:

RTN:

RTN: Signal

Signal

Signal r

r

r eturn

eturn

4-

4- 12V

12V

12V high-level

high-level

high-level brake

brake

brake and

and

and m

m

m otor

otor

otor temperature

temperature

temperature input

input

5-

5- Throttle

Throttle

Throttle analog

analog

analog input,

input,

input, 0-5V

0-5V

6-

6- B

B

B rake

rake

rake analog

analog

analog input

input

input ,

,

, 0-5V

0-5V

7-

7- 5V:

5V:

5V: 5V

5V

5V supply

supply

supply output.

output.

output. <40mA

<40mA

8-

8- Micro_SW:

Micro_SW:

Micro_SW: Throttle

Throttle

Throttle switch

switch

switch input

input

9-

9- R

R

R evers

evers

evers ing

ing

ing switch

switch

switch input

input

10-

10- Brake

Brake

Brake switch

switch

switch input

input

11-

11- Hall

Hall

Hall phase

phase

phase C

C

12-

12- Hall

Hall

Hall phase

phase

phase B

B

13-

13- Hall

Hall

Hall phase

phase

phase A

A

14-

14- RTN:

RTN:

RTN: Signal

Signal

Signal r

r

r eturn

eturn

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Notes:

1.

1. All

All

All RTN

RTN

RTN pins

pins

pins are

are

are internally

internally

internally connected.

connected.

2.

2. Two

Two

Two PWR

PWR

PWR pins,

pins,

pins, J1-

J1-

J1- 1

1

1 and

and

and J2-1,

J2-1,

J2-1, are

are

are internally

internally

internally connected.

connected.

connected. It

It

It ’

’

’ s

s

s recommended

recommended

recommended to

to

to use

use

use J1-

J1-

J1- 1

1

to

to supply

supply

supply peripherals

peripherals

peripherals like

like

like alarm

alarm

alarm and

and

and contactor

contactor

contactor .

.

. Twist

Twist

Twist peripheral

peripheral

peripheral wires

wires

wires with

with

with PWR

PWR

PWR is

is

is the

the

preferred

preferred for

for

for EMC.

EMC.

3.

3. Kelly

Kelly

Kelly Ammeter

Ammeter

Ammeter positive

positive

positive connect

connect

connect to

to

to 5V

5V

5V power

power

power supply

supply

supply of

of

of controller,

controller,

controller, negative

negative

negative to

to

to J1-2.

J1-2.

4.

4. Switch

Switch

Switch to

to

to ground

ground

ground is

is

is active.

active.

active. Open

Open

Open switch

switch

switch is

is

is inactive

inactive

inactive .

.

Caution:

• D

D

D o

o

o not

not

not apply

apply

apply power

power

power until

until

until you

you

you are

are

are certain

certain

certain the

the

the controller

controller

controller wiring

wiring

wiring is

is

is correct

correct

correct and

and

and has

has

has been

been

double

double checked.

checked.

checked. W

W

W iring

iring

iring faults

faults

faults will

will

will damage

damage

damage the

the

the controller.

controller.

• Ensure

Ensure

Ensure that

that

that the

the

the B-

B-

B- wiring

wiring

wiring is

is

is securely

securely

securely and

and

and properly

properly

properly connected

connected

connected before

before

before applying

applying

applying power.

power.

• T

T

T he

he

he preferred

preferred

preferred connection

connection

connection of

of

of the

the

the system

system

system contactor

contactor

contactor or

or

or circuit

circuit

circuit breaker

breaker

breaker is

is

is in

in

in series

series

series with

with

with the

the

the B+

B+

line.

• All

All

All contactors

contactors

contactors or

or

or circuit

circuit

circuit breakers

breakers

breakers in

in

in the

the

the B+

B+

B+ line

line

line must

must

must have

have

have precharge

precharge

precharge resistors

resistors

resistors across

across

across their

their

contacts.

contacts. L

L

L ack

ack

ack of

of

of even

even

even one

one

one of

of

of these

these

these precharge

precharge

precharge resistors

resistors

resistors may

may

may severely

severely

severely damage

damage

damage the

the

controller

controller at

at

at switch-on.

switch-on.

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3.2.2

3.2.2 Wiring

Wiring

Wiring of

of

of BLDC

BLDC

BLDC Motor

Motor

Motor Controller

Controller

Figure

Figure 5

5

5 :

:

: Standard

Standard

Standard Wiring

Wiring

Wiring for

for

for Controllers

Controllers

Controllers Rated

Rated

Rated Equal

Equal

Equal or

or

or Lower

Lower

Lower Than

Than

Than 120

120

V.

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11

Figure

Figure 6

6

6 :

:

: BLDC

BLDC

BLDC controller

controller

controller preferred

preferred

preferred wiring

wiring

(24V

(24V supply

supply

supply is

is

is preferred)

preferred)

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3.2.

3.2. 3

3

3 Communication

Communication

Communication Port

Port

A

RS232 port is provided to communicate with host computer for calibration and configuration.

Figure

Figure 7:

7:

7: standard RS232 I nterface

3.3

3.3 Installation

Installation

Installation Check

Check

Check List

List

Before operating the vehicle, complete the following checkout procedure s . Use LED code

as a reference as listed in

T

able 1 .

Caution:

• Put

Put

Put the

the

the vehicle

vehicle

vehicle up

up

up on

on

on blocks

blocks

blocks to

to

to get

get

get the

the

the drive

drive

drive wheels

wheels

wheels off

off

off the

the

the ground

ground

ground before

before

before beginning

beginning

beginning these

these

tests.

• Do

Do

Do not

not

not allow

allow

allow anyone

anyone

anyone to

to

to stand

stand

stand directly

directly

directly in

in

in front

front

front of

of

of or

or

or behind

behind

behind the

the

the vehicle

vehicle

vehicle during

during

during the

the

the checkout.

checkout.

• Make

Make

Make sure

sure

sure the

the

the PWR

PWR

PWR switch

switch

switch and

and

and the

the

the brake

brake

brake is

is

is off

off

• Use

Use

Use well-insulated

well-insulated

well-insulated tools.

tools.

•

Make sure the wire is connected correctly

•

Turn the PWR switch on. T he Green LED stay on steadily and Red LED turns off when the

controller operate s normally. If this does not happen, check continuity of the PWR and

return.

•

T he fault code will be detected automatically at restart .

• With the brake switch open, select a direction and operate the throttle. The motor should

spin in the selected direction. V erify wiring or voltage and the fuse if it does not . The motor

should run faster with increasing throttle. If not, refer to the Table 1 LED code, and correct

the fault as determined by the fault code.

•

Take the vehicle off the blocks and drive it in a clear area. It should have smooth

acceleration and good power.

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3.3

Page 13

Chapter

Chapter 4

4

4 Maintenance

Maintenance

There are no user-serviceable parts inside the controllers. Do not attempt to open the controller as this will void your warranty. However, periodic, exterior clea n ing of the controller should be carried out.

The controller is a high power ed device. When working with any battery powered vehicle, proper safety precautions should be taken that include, but are not limited to, proper training, wearing eye protection, avoid ance of loose clothing , hair and jewelr

y.

A lways use insulated

tools.

4.1

4.1 Cleaning

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, starting with battery positive.

• Discharge the capacitors in the controller by connecting a load (such as a contactor coil,

resistor 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. M ake sure that the controller is dry before reconnecting the battery.

•

• Make sure the connections to the bus bars , if fitted, are tight. T o avoid physically stressing

the bus bars use two, well-insulated wrenches.

4.2

4.2 Configuration

Configuration

You can configure the controller with a host computer through either an RS232 or USB port .

• Disconnect motor wiring from controller.

• 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 .

• Use straight through RS232 cable or USB converter provide d 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.

Download the free configuration software from ：

http://www.kellycontroller.com/support.php

Caution:

• Make

Make

Make certain

certain

certain that

that

that the

the

the motor

motor

motor is

is

is disconnected

disconnected

disconnected before

before

before trying

trying

trying to

to

to run

run

run the

the

the Configuration

Configuration

Software!

• Configuration

Configuration

Configuration software

software

software will

will

will be

be

be regularly

regularly

regularly updated

updated

updated and

and

and published

published

published on

on

on the

the

the website.

website.

website. Please

Please

U

U pdate

pdate

pdate your

your

your Configuration

Configuration

Configuration Software

Software

Software regularly .

regularly.

regularly. You

You

You must

must

must uninstall

uninstall

uninstall the

the

the older

older

older version

version

before

before updating.

updating.

• When

When

When setting

setting

setting "Hall

"Hall

"Hall Sensor

Sensor

Sensor Type"

Type"

Type" in

in

in GUI,

GUI,

GUI, do

do

do not

not

not use

use

use "Auto-Check".

"Auto-Check".

"Auto-Check". T

T

T his

his

his has

has

has been

been

deleted

deleted from

from

from the

the

the newer

newer

newer configuration

configuration

configuration software

software

software versions.

versions.

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Table

Table 1:

1:

1: LED

LED

LED CODES

CODES

Green

Green LED

LED

LED Codes

Codes

LED Code Explanation

S olution

Green O ff

No power or switched off

1. Check if all wires are correct .

2. Check fuse and power supply.

Green On

Normal operation

That’s great!

You

got solution! Green & Red are both On

1. Software still upgrading.

2. Supply voltage too low or battery too high 3 . The controller is damaged . C ontact Kelly about a warranty repair.

Red

Red LED

LED

LED Codes

Codes

LED Code Explanation

S olution

1,2 ¤ ¤¤

O ver voltage error

1. Battery voltage is too high for the controller. C heck battery volts and configuration.

2. Regeneration over-voltage. Controller will have cut back or s topped regen .

3. This only accurate to ± 2% upon Overvoltage setting.

1,3 ¤ ¤¤¤

Low voltage error

1. The controller will clear after 5 seconds if battery

volt s returns to normal.

2. C heck battery volts & recharge if required.

1,4 ¤ ¤¤¤¤

Over t emperature warning

1. Controller case temperature is above 90 ℃ .

Current will be limited. R educe controller loading or switch Off until controller cools down.

2. Clean or improve heatsink or fan.

2,1 ¤¤ ¤

Motor did not s tart

Motor did not reach 25 electrical RPM within 2 seconds of start -up . H all sensor or phase wiring problem.

2,2 ¤¤ ¤¤

I nternal volts fault

1. Measure that B+ & PWR are correct when measured to 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 . C ontact Kelly about a warranty repair.

2,3 ¤¤ ¤¤¤

O ver temperature

The controller temperature has exceeded 100 ℃ . The controller will be stopped but will restart when temperature falls below 80 ℃ .

2,4 ¤¤ ¤¤¤¤

Throttle error at power - up

T hrottle signal is higher than the preset ‘ dead zone’at P ower O n . Fault clears when throttle is released.

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3,1 ¤¤¤ ¤

Frequent reset

May be caused by over -voltage , bad motor intermittent earthing problem , bad wiring , etc .

3,2 ¤¤¤ ¤¤

Internal r eset

May be caused by some transient fault condition like a temporary over-current, momentarily h igh or low battery voltage . This can happen during normal operation .

3,3 ¤¤¤ ¤¤¤

Hall throttle is open or short-circuit

When the throttle is repaired , a restart will clear the fault.

3,4 ¤¤¤ ¤¤¤¤

Non-zero throttle on direction change

Controller won ’ t allow a direction change unless the throttle or speed is at zero. F ault clears when throttle is released.

4,1 ¤¤¤¤ ¤

Regen or Start-up over-voltage

Motor drive is disabled if an over-voltage is detected at start-up or during regen. The voltage threshold detection level is set during configuration.

4, 2 ¤¤¤¤ ¤¤

Hall sensor error

1. I ncorrect or loose wir ing or a damaged hall

sensor .

2. Also be caused by incorrect hall angle

configuration (60 degree or 120 degree).

4, 3 ¤¤¤¤ ¤¤¤

M otor over-temperature

M otor temperature has exceeded the configured maximum. The controller will s hut down until the motor temperature cools down.

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 t his problem disappear s , the fault will clear and the max output phase current will return to normal.

T he Red LED flashes once at power on as a confidence check and then normally stays Off. “ 1, 2 ” means the Red flashes once and after a second pause, flashes twice. The pause time between multiple flash code groups is two seconds.

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Table

Table 2

2

2 :

:

: KBL

KBL

KBL Controller

Controller

Controller CAN

CAN

CAN Commands

Commands

Commands List

List

V

ersion

ersion 1.1

1.1

You

You should

should

should specify

specify

specify when

when

when sending:

sending:

ID:

ID: Our default ID is 0x6B, so only the data frame with ID 107 can be received by our controller.

However, it can be set by configuration program.

Frame

Frame type:

type:

type: data frame

Frame

Frame format:

format:

format: standard 11 bits ID

Length:

Length: the number of data field bytes Data

Data

Data field:

field:

field: d ata [0] is the command which indicates the operation.

Controller

Controller response

response

response :

:

ID:

ID: The controller sends data frames with ID 115, 0x73. It also can be set by configuration program. Frame

Frame

Frame type:

type:

type: data frame

Length:

Length: the number of data field bytes Data

Data

Data field:

field:

field: The controller sends a data frame in response.

Commands

Commands definitions

definitions

C ommand CCP

CCP

CCP _FLASH_READ

_FLASH_READ

Length 3 data[0] 0xF2 data[ 1 ] INFO_MODULE_NAME data[ 2 ] 8 Controller response Length 8 data[0]~data[7] Controller ’ s model in ASCII format, 8 bytes. Description: Getting controller ’ s mod el no. E.g. 0x4B,0x42,0x4C is 'K' , 'B', 'L', 0x30 is '0' .

INFO_MODULE_NAME constant is defined as 64.

C ommand CCP

CCP

CCP _FLASH_READ

_FLASH_READ

Length 3 data[0] 0xF2 data[1] INFO_SOFTWARE_VER data[2] 2 Controller response Length 2 data[0]~data[1] software version in BCD alike format, two bytes.

Description: Getting controller ’ s software version, it also define as the controller ’ s version, BCD alike format storage. E.g. 0x0A,0x01 should be parsed to ASCII characters ‘ 0 ’ ‘ A ’ ‘ 0 ’ ‘ 1 ’ as the software version. INFO_SOFTWARE_VER constant is defined as 83.

Command CCP

CCP

CCP _FLASH_READ

_FLASH_READ

Length 3

data [0] 0xF2

data [1] CAL_TPS_DEAD_ZONE_LOW

data [2] 1

Controller response

Length 1

data [0] TPS_Dead_Zone _L ow

Desccription: Getting controller ’ s Throttle low-end dead zone. CAL_TPS_DEAD_ZONE_LOW constant is defined as 4. The maximum value of Throttle is 200. If the value of Throttle L ow-end D ead Z one is 40, indicating 20% low-end dead zon e. (40/200 is 20%.)

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Command CCP

CCP

CCP _FLASH_READ

_FLASH_READ

Length 3

data [0] 0xF2

data [1] CAL_TPS_DEAD_ZONE_HIGH

data [2] 1

Controller response

Length 1

data [0] TPS_Dead_Zone _ High

Desccription: Getting controller ’ s Throttle high -end dead zone. CAL_TPS_DEAD_ZONE_HIGH constant is defined as 5. The maximum value of Throttle is 200. If the value of Throttle High -end D ead Z one is 160, indicating 80% high -end dead zon e. (160/200 is 80%.)

Command CCP

CCP

CCP _FLASH_READ

_FLASH_READ

Length 3

data [0] 0xF2

data [1] CAL_BRAKE_DEAD_ZONE_LOW

data [2] 1

Controller response

Length 1

data [0] Brake_Dead_Zone_Low

Desccription: Getting controller ’ s Brake low-end dead zone. CAL_BRAKE_DEAD_ZONE_LOW constant is defined as 38. The maximum value of Brake is 100. If the value of Brake Low -end D ead Z one is 20, indicating 20% low-end dead zon e. (20/100 is 20%.)

Command CCP

CCP

CCP _FLASH_READ

_FLASH_READ

Length 3

data [0] 0xF2

data [1] CAL_BRAKE_DEAD_ZONE_HIGH

data [2] 1

Controller response

Length 1

data [0] Brake_Dead_Zone_High

Desccription: Getting controller ’ s Brake high -end dead zone. CAL_BRAKE_DEAD_ZONE_HIGH constant is defined as 39. The maximum value of Brake is 100. If the value of Brake High -end D ead Z one is 80, indicating 80% high -end dead zon e. (80/100 is 80%.)

C ommand CCP

CCP

CCP _A2D_BATCH_READ

_A2D_BATCH_READ

_A2D_BATCH_READ 1

1

Length 1

data[0] 0x1b

Controller response

Length 5

data[0] Brake A/D

data[1] TPS A/D

data[ 2 ] Control p ower A/D

data[ 3 ] Vs A/D

data[ 4 ] B+ A/D

Description: Data batch reading.

1) For control power, B+, A/D value and voltage mapping relation is: V = Vad / 4.06. (For 24V ,36V, 48V controlle r ) ; V = Vad / 2.71 . (For 72 V controller) ; V = Vad / 1.84. (For 120 V controlle r ) .

2) Vs is defined as the 5V power supply for Hall sensor, control panel,ect. A/D value

and voltage mapping relation is: 120 ~ 134 mapping to 4.75 ~ 5.25 V .

3) Brake and TPS are defined as the Brake and the Throttle analog input. A/D value

and voltage mapping relation is: 0 ~ 255 mapping to 0 ~ 5

V.

C ommand CCP

CCP

CCP _A2D_BATCH_READ

_A2D_BATCH_READ

_A2D_BATCH_READ 2

2

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Length 1 data[0] 0x1a Controller response Length 6 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 / 4.06. (For 24V ,36V, 48V controlle r ) ; V = Vad / 2.71 . (For 72 V controller) ; V = Vad / 1.84. (For 120 V controlle r ) .

2) Ia, Ib and Ic are defined as the three phase current.

C ommand CCP

CCP

CCP _MONITOR

_MONITOR

_MONITOR 1

1

Length 1 data[0] 0x33 Controller response Length 6 data[0] PWM data[1] enable motor rotation data[ 2 ] motor temperature data[ 3 ] Controller’s temperature data[ 4 ] temperature of high sid e FETMOS heat sink data[ 5 ] temperature of low side FETMOS heat sink Description: Data batch reading.

3. PWM is output duty cycle, from 0 to 100.

4. data[1] indicates enabling motor rotation or disabling. 1 - enable , 0 - disable .

5. data [2] is defined as the temperature of motor in Celsius temperature . If the

temperature sensor is not connected, the controller returns 0xFF.

6. data[3]-data[5] are defined as controller inside temperature in Celsius temperature .

The value of data[4] and data[ 5 ] are inaccurate below 30 ℃ .

C ommand CCP

CCP

CCP _MONITOR

_MONITOR

_MONITOR 2

2

Length 1 data[0] 0x37 Controller response Length 3 data[ 0 ] MSB of mechanical speed in RPM data[ 1 ] LSB of mechanical speed in RPM data[ 2 ] present current accounts for percent of the rated current of controller Description: Data batch reading.

1) Mechanical speed calculation: (MSB << 8) | LSB. If the speed out data is not match the real speed value, please configure the motor poles calibration data of the controller based on the driven motor.

C ommand COM_SW_ACC

COM_SW_ACC

Length 2 data[0] 0x42 data[0] COM_READING Controller response Length 1 data[0] C urrent throttle switch status Description: Getting Throttle switch status, 1 – active, 0 – inactive. COM_READING constant is

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defined as 0.

C ommand COM_SW_BRK

COM_SW_BRK

Length 2 data[0] 0x43 data[0] COM_READING Controller response Length 1 data[0] C urrent Brake switch status Description: Getting Brake swith st atus, 1 – active, 0 – inactive. COM_READING constant is defined

as 0.

C ommand COM_SW_REV

COM_SW_REV

Length 2 data[0] 0x44 data[0] COM_READING Controller response Length 1 data[0] C urrent Reverse sw itch status Description: Getting Reverse swith status, 1 – active, 0 – inactive. COM_READING constant is

defined as 0.

NOTICE:

1. CAN bus rate should be configured to 1Mbit/s.

2.If the command is out of above commands Controller response

Length 1 data[0] CCP_INVALID_COMMAND Description : CCP_INVALID_COMMAND constant is defined as 0xe3.

Contact

Contact Us:

Us:

Kelly

Kelly Controls,

Controls,

Controls, LLC

LLC

Home

Home Page:

Page:

http://www.KellyController.com

E-mail:

Support@KellyController.com

Phone:

(01) 224 637 5092

Kelly KBL48101, KBL24151, KBL24201, KBL24301, KBL48151 User Manual

Specifications and Main Features

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User Manual