Kelly KHB High Power Brushless Motor Controller

General Functions

• Extended fault detection and protection. The LED flashing pattern indicates the fault sources. Green LED indicates normal operation. Controller will shut down in some fault conditions.
• 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°C case temperature, shutting down at 100°C.
• Enhanced regen brake function. A novel ABS technique provides powerful and smooth regen.
• 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.
• Pulsed reverse alarm output.
• 3 switch inputs which are activated by connection to Ground. Default to throttle switch, brake switch and reversing switch.
• 3 analog 0-5V inputs that default to throttle input, brake input and motor temperature input.
• Provision of a +5 volt output to supply various kinds of sensors, including Hall effect type.
• Main contactor driver. Cutting off the power if any fault is detected.
• Current meter to display both drive and regen current. Save shunt.
• 3 hall position sensor inputs. Open collector, pull up provided.
• 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).
• 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.
• Maximum reverse power is configurable to half power.
• Configurable 12V brake signal input, in lieu of motor temperature sensor.
• Optional joystick throttle. A bi-symmetrical 0-5V signal for both forwarding and reversing
• Configurable motor over-temperature detection and protection with the recommended thermistor KTY84-130.
• Optional CAN bus.
• Supply voltage 8V-30V

Features

• Opto-isolated technology achieve stability.
• 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. Support fan or water cooling.
• 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, 0-5K or 0-5V analog signal variable regen for KHB and HP controllers.
• 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: 2 or 3-wire pot, or hall sensor throttle can work with KHB and HIP controllers.
• 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 depending on the model: usually less than 2mA.
• 5V Sensor Supply Current: 40mA.
• Controller supply voltage range, PWR, 8 to 30V (24V preferred)
• Controller input power, PWR: less than 10W.
• Configurable battery voltage range, B+. Max operating range: 18V to 136V for controller rated equal 120V. 18V to 180V for controller rated equal 144V.
• 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).
• Motor Current Limit, 1 minute: 150A - 1000A, depending on the model.
• Motor Current Limit, continuous: 75A - 500A, depending on the model.
• Max Battery Current : Configurable..