Kelly KEB Series User manual

Kelly Ebike Brushless DC Motor Controller User’s Manual V 3.3

Kelly KEB Brushless Motor

Controller User’s Manual

Devices Supported:

KEB48220

KEB48221

KEB48300

KEB48301

KEB48400

KEB48401

KEB48600

KEB48601

KEB72330

KEB72331

KEB72450

KEB72451

KEB72600

KEB72601

KEB72800

KEB72801X

Rev.3.3

Mar. 2011

Kelly Ebike Brushless DC Motor Controller User’s Manual V 3.3

Page 1

Contents

Chapter 1 Introduction.........................................................................................2

1.1 Overview.................................................................................................. 2

Chapter 2 Main Features and Specifications .......................................................3

2.1 General functions..................................................................................... 3

2.2 Features .................................................................................................. 4

2.3 Specifications .......................................................................................... 4

2.4 Models..................................................................................................... 5

Chapter 3 Wiring and Installation.........................................................................6

3.1 Mounting the Controller ........................................................................... 6

3.2 Connections............................................................................................. 7

3.3 Installation Check List............................................................................ 10

Chapter 4 Maintenance .....................................................................................11

4.1 Cleaning ................................................................................................ 11

4.2 Configuration......................................................................................... 11

Table 1: LED CODES........................................................................................12

Kelly Ebike Brushless DC Motor Controller User’s Manual V 3.3

Page 2

Chapter 1 Introduction

1.1 Overview

This manual introduces the Kelly ebike brushless DC 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 KEB motor controllers provide efficient, smooth and quiet controls for

electric bicycles, electric motorcycles, scooters, etc. It outputs high taking off current, and

strictly limit battery current. It can work with relative small battery, but provide good acceleration

and hill climbing. It uses high power MOSFET’s and, PWM to achieve efficiencies of up to 99%.

In most cases, Powerful microprocessor brings in comprehensive and precise control to the

controllers. It also allows users to adjust parameters, conduct tests, and obtain diagnostic

information quickly and easily.

Kelly Ebike Brushless DC Motor Controller User’s Manual V 3.3

Page 3

Chapter 2 Main Features and Specifications

2.1 General functions

(1) Extended fault detection and protection. 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.

(3) Built-in current loop and over current protection.

(4) Motor temperature input and protection. Configurable range.

(5) Cutting back current at low temperature and high temperature to protect battery and

controller. The current will ramp down quickly if controller temperature is higher than 90ﹾＣ,

and shut down at 100ﹾＣ. Low temperature current ramping down usually starts at 0ﹾＣ.

(6) The controller keeps monitoring voltage during regen. It will cut back current or stop regen if

voltage is too high.

(7) Configurable to limit max reverse speed to half of max forward speed

(8) Configurable and programmable with RS-232. Software upgradeable. Windows GUI

provided.

(9) Provide power supply (5V) for hall sensors and other sensors.

(10) 3 switch inputs: Default to throttle switch, brake switch and reversing switch. Closing to

ground is to activate.

(11) 3 analog inputs, 0-5V: Default to throttle input, brake input and motor temperature input.

(12) Configurable boost switch. Output can arrive at the maximum current if the switch is

enabled and turned on.

(13) Configurable turbo switch. Limit max power to half if the switch is enabled and turned on.

(14) Configurable max reverse power to half.

(15) Enhanced regen brake function. Novel ABS technique provides powerful and smooth

regen.

(16) Configurable 12V brake signal input, instead of motor temperature sensor.

(17) Optional joystick throttle. Single 0-5V signal for both forwarding and reversing.

(18) Thermal overload detection and protection to safeguard the motor from over temperature

(designed using Silicon temperature sensors KTY83-122).

(19) 3 hall position sensor inputs. Open collector, pull up provided.

(20) Optional supply voltage 8V-30V.

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!).

Kelly Ebike Brushless DC Motor Controller User’s Manual V 3.3

Page 4

2.2 Features

•Specially designed for electric bicycle and scooter.

•Intelligence with powerful microprocessor.

•Synchronous rectification, ultra low drop, fast PWM to achieve very high efficiency.

•Electronic reversing.

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

•Voltage monitoring on voltage source 12V and 5V.

•Current sense on all 3 motor phases.

•Current control loop.

•Hardware over current protection.

•Hardware over voltage protection.

•Support torque mode, speed mode, and balanced mode operation.

•Configurable limit for motor current and battery current.

•Battery current limiting available, doesn’t affect taking off performance.

•More startup current ,can get more startup speed.

•Low EMC.

•LED fault code.

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

battery voltage.

•Rugged aluminum housing for maximum heat dissipation and harsh environment.

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

•Thermal protection: current cut back, warning and shutdown on high temperature.

•Configurable 60 degree or 120 degree hall position sensors.

•Support motors with any number of poles.

•Up to 40,000 electric RPM standard. Optional high speed 70,000 ERPM, and ultra high speed

100,000 ERPM. (Electric RPM = mechanical RPM * motor pole pairs).

•Brake switch is used to start regen.

•0-5V brake signal is used to command regen current.

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

0-5V analog signal variable regen.

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

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

•Easy installation: 3-wire potentiometer will work.

•Current meter output.

•Standard PC/Laptop computer to do programming. No special tools needed.

•User program provided. Easy to use. No cost to customers.

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.

Kelly Ebike Brushless DC Motor Controller User’s Manual V 3.3

Page 5

•Supply Current, PWR, 150mA.

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

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

•Analog Brake and Throttle Input: 0-5 Volts. Producing 0-5V signal with 3-wire pot.

•Full Power Operating Temperature Range: 0ﹾＣto 50ﹾＣ(controller case temperature).

•Operating Temperature Range: -30ﹾＣto 90ﹾＣ,100ﹾＣshutdown(controller case temperature).

•Peak Phase Current, 30 seconds: 100-350A, depending on the model.

•Continuous Phase Current Limit: 50A-150A, depending on the model.

•Maximum Battery Current: Configurable

2.4 Models

The naming regulations of the Kelly KEB motor controller model:

Kelly Ebike Brushless DC Motor Controller User’s Manual V 3.3

Page 6

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.

To ensure full rated output power, the controller should be fastened to a clean, flat metal

surface with four screws. Applying silicon gel or other thermal conductive material to contact

surface will enhance thermal performance.

Sufficient heat sink and airflow are required for high power application.

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

Height: 62 millimeters

Figure 1: mounting holes’dimensions (dimensions in millimeters)

Kelly Ebike Brushless DC Motor Controller User’s Manual V 3.3

Page 7

3.2 Connections

3.2.1 Front Panel of KEB Motor Controller:

Five metal bars and a 14pin rugged connector are provided for connecting to the battery,

motor and control signals in the front of the controller shown as Figure 2.

Figure 2: Front panel of KEB motor controller

B+: battery positive

B-: battery negative

A: Output U/1/A phase

B: Output V/2/B phase

C: Output W/3/C phase

Figure 3: The connecting diagram of J2

J2 Pin Definition

1- PWR: Controller power supply

2- RTN: Signal return, or power supply ground

3- RTN: Signal return

4- 12V high-level brake and motor temperature input

5- Throttle analog input, 0-5V

6- Brake analog input, 0-5V

7- 5V: 5V supply output, <40mA

8- Micro_SW: Throttle switch input.

Kelly Ebike Brushless DC Motor Controller User’s Manual V 3.3

Page 8

9- Reversing switch input

10-Brake switch input

11-Hall phase C

12-Hall phase B

13-Hall phase A

14-RTN: Signal return

Notes: 1. All RTN pins are internally connected. RTN is internally connected to B-.

2. Switch to ground is active. Open switch is inactive

Caution: Make sure all connections are correct before applying power. Otherwise it may

damage the controller! Please securely wire B- before applying power. It's preferred to place

contactor or breaker on B+. Please place precharge resistor on any breaker! It can cause

damage without it!!!

Kelly Ebike Brushless DC Motor Controller User’s Manual V 3.3

Page 9

3.2.2 Standard Wiring of KEB Motor Controller

Figure 4: KEB controller standard wiring

(Battery voltage can be used for controller supply)

This manual suits for next models

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