Kelly KEB48200 User manual

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

Kelly KEB Brushless Motor

Controller User’s Manual

Devices Supported:

KEB48200

KEB48201

KEB48300

KEB48301

KEB48400

KEB48401

KEB48600

KEB48601

KEB72300

KEB72301

KEB72450

KEB72451

KEB72600

KEB72601

KEB72800

KEB72801X

KEB72100

KEB72101

Rev.3.3

July 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. 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”setting.

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

(4) Configurable motor temperature protection range.

(5) Current cutback at low temperature and high temperature to protect battery and controller.

The current begins to ramp down at 90ﹾＣcase temperature, shutting down at 100ﹾＣ.

(6) The controller keeps monitoring battery recharging voltage during regenerative 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. Default to throttle switch,

brake switch and reversing switch.

(11) 3 analog inputs 0-5V inputs that default to throttle input, brake input and motor temperature

input.

(12) Configurable boost switch. Enables the maximum output power achievable if the switch is

turned on.

(13) Configurable economy switch. Limits the maximum current to half if the switch is turned on.

(14) Maximum reverse power is configurable to half power.

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

regen.

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

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

(18) Configurable motor over-temperature detection and protection with the recommended

thermistor 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 does not replace the function of a mechanical

brake. A mechanical 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 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 at 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 is used 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: 100-450A, depending on the model.

•Continuous Phase Current Limit: 50A-190A, depending on the model.

•Maximum Battery Current: Configurable

2.4 Models

The naming regulations of the Kelly KEB motor controller model:

KEB72300

The eighth letter represents regeneration

(0:non-regen;1:with-regen).

The sixth and seventh letters = the max actual output power of controller *

10, except letters ‘10’(unit:kW). ‘10’represents 10kW.

The first three letters represent Kelly’s electric

bicycle motor controller.

The fourth and fifth letters represent nominal

voltage.

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 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 screws. Applying silicon grease or some other thermal conductive material to

contact surface will enhance thermal performance.

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

controller.

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

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

Page 7

Height: 62 millimeters

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

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

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

Page 8

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

8. Micro_SW: Throttle switch input.

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:

•Do not apply power until you are certain the controller wiring is correct and has been

double checked. Wiring faults will damage the controller.

•Ensure that the B- wiring is securely and properly connected before applying power.

•The preferred connection of the system contactor or circuit breaker is in series with the B+

line.

•All contactors or circuit breakers in the B+ line must have precharge resistors across their

contacts. Lack of even one of these precharge resistors may severely damage the

controller at switch-on.

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)

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