Kelly KBL Brushless Motor Controller

General Functions

• Extended fault detection and protection. The LED flashing pattern indicates the fault sources.
• 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.
• Built-in current loop and over current protection.
• Configurable motor temperature protection range.
• Current cutback at low temperature and high temperature to protect battery and controller. The current begins to ramp down at 90 Ccase temperature, shutting down at 100 C.
• 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.
• Maximum reverse speed is configurable to half of max forward speed.
• 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).
• Provision of a +5 volt output to supply various kinds of sensors, including Hall effect type.
• 3 switch inputs which are activated by connection to Ground. Default to throttle switch, brake switch and reversing switch. Closing to ground is to activate.
• 3 analog 0-5V inputs that default to throttle input, brake input and motor temperature input.
• Pulsed reverse alarm output.
• Main contactor driver. Cutting off the power if any fault is detected.
• Current meter to display both drive and regen current. Save shunt!
• Configurable boost switch. Enables the maximum output power achievable if the switch is turned on.
• Configurable economy switch. Limits the maximum current to half if the switch is turned on. Boost and Economy used the same pin as J2-6 (brake-AN). Needless to say, you may not use J2-6 (brake-AN) as brake analog regen mode if you want to use Boost or Economy function. Boost or Economy can’t be enabled at the same time in the user program.
• Maximum reverse power is configurable to half power.
• Enhanced regen brake function. A novel ABS technique provides powerful and smooth regen.
• Configurable 12V brake signal input, instead of motor temperature sensor.
• Optional joystick throttle. A bi-symmetrical 0-5V signal for both forwarding and reversing. If software version is 0406 or above, joystick can can be enabled or disabled in the user program now.
• Configurable motor over-temperature detection and protection with the recommended thermistor KTY84-130 or KTY83-122.
• 3 hall position sensor inputs. Open collector, pull up provided.
• Optional CAN bus. CAN bus is not included in KBL controller. By default, if customer don’t pay it.
• Optional supply voltage 8-30V.
• Cruise control. Can not be activated in reversing direction. If software version is 0406 or above, cruise control can be enabled or disabled in the user program now. If you hold throttle at certain position about 3-4 seconds, the controller will get into Cruise control.

Features

• Intelligence with powerful microprocessor.
• Synchronous rectification, ultra low drop and 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.
• 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).
• Support three modes of regenerative braking: brake switch regen, release throttle regen, 0-5V analog signal variable regen.
• Configurable high pedal protection: the controller will not work if high throttle is detected at power on.
• Current multiplication: Take less current from battery, output more current to motor.
• Easy installation: 3 wire potentiometer can work.
• Remote fault code LED driver.
• 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.

Specifications

• Frequency of Operation: 16.6kHz.
• Standby Battery Current: < 0.5mA.
• 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 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. Producing 0-5V signal with 3-wire pot.
• Reverse Alarm, Main Contactor Coil Driver, Meter.
• Full Power Operating Temperature Range: 0°C to 50°C (controller case temperature).
• Operating Temperature Range: -30°C to 90°C, 100°C shutdown (controller case temperature).
• Boost Current, 10 seconds: 150A-550A, depending on the model.
• Motor Current Limit, 1 minute: 100A-500A, depending on the model.
• Motor Current Limit, continuous: 60A-200A, depending on the model.
• Max Battery Current : Configurable.