V 3.3
Kelly KHB High Power Brushless Motor Controller
User’s Manual
Devices Supported:
| KHB72601 | KHB72701 | KHB72101 | ||
| KHB12151 | KHB12201 | KHB12251 | KHB12301 | KHB12401 |
| KHB12601 | KHB12801 | |||
| KHB14201 | KHB14301 | KHB14401 | KHB14601 |
Rev.3.3
Feb. 2025
Chapter 1 Introduction
1.1 Overview
The manual introduces Kelly high power BLDC motor controllers’ features, installation and 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 motor controllers provide high efficient, smooth and quite controls for electric motorcycle, forklift, hybrid vehicle, electrical vehicle, electric boat, as well as industry motor speed or torque control. It uses high power MOSFET, PWM to achieve efficiency 99% in most cases. Powerful microprocessor brings in comprehensive and precise control to the controllers. It also allows users to set parameters, conduct tests, and obtain diagnostic information quickly and easily.
Chapter 2 Features and Specifications
2.1 General functions
(1) Extended fault detection and protection. LED flashing for fault code 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’s temperature is higher than 90°C, and shut down at 100°C. Low temperature current ramping down usually starts at 0°C.
(6) The controller keeps monitoring voltage during regen. It will cut back current then cut off regen if voltage is going 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 reverse switch. Closing to ground is to activate.
(11) 3 analog inputs, 0-5V: Default to throttle input, brake input and motor temperature input.
(12) PWMable reverse alarm output. Recirculation diodes provided.
(13) Main contactor driver. Cutting off the power if any fault is detected.
(14) Current meter to display both drive and regen current. Save shunt.
(15) Configurable boost switch. Output can arrive at the maximum current if the switch is enabled and turned on.
(16) Configurable turbo switch. Limiting max power to half if the switch is enabled and turned on.
(17) Configurable max reverse power to half.
(18) Enhanced regen brake function. Novel ABS technique provides powerful and smooth regen.
(19) Configurable 12V brake signal input, instead of motor temperature sensor.
(20) Optional joystick throttle. Single 0-5V signal for both forwarding and reversing
(21) Thermal overload detection and protection to safeguard the motor from over temperature, with recommended Silicon temperature sensors KTY83-122.
(22) 3 hall position sensor inputs. Open collector, pull up provided.
(23) Optional CAN bus.
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!).
2.2 Features
1) Opto-isolated technology achieve stability.
2) Intelligence with powerful microprocessor.
3) Synchronous rectification, ultra low drop and fast PWM to achieve very high efficiency.
4) Electronic reversing.
5) Voltage monitoring on 3 motor phases, bus, and power supply.
6) Voltage monitoring on voltage source 12V and 5V.
7) Current sense on all 3 motor phases.
8) Current control loop.
9) Hardware over current protection.
10) Hardware over voltage protection.
11) Support torque mode, speed mode, and balanced mode operation.
12) Configurable limit for motor current and battery current.
13) Low EMC.
14) LED fault code.
15) Battery protection: current cutback, warning and shutdown at configurable high and low battery voltage.
16) Rugged aluminum housing for maximum heat dissipation and harsh environment.
17) Rugged high current terminals, and rugged aviation connectors for small signal.
18) Thermal protection: current cut back, warning and shutdown on high temperature.
19) Configurable 60 degree or 120 degree hall position sensors.
20) Support motors with any number of poles. Up to 40,000 electric RPM standard. Optional high speed 70,000 ERPM. (Electric RPM = mechanical RPM * motor pole pairs).
21) Support three modes of regenerative braking: brake switch regen, release throttle regen, 0-5V analog signal variable regen.
22) Configurable high pedal protection: Disable operation if power up with high throttle.
23) Current multiplication: Take less current from battery, output more current to motor.
24) Easy installation: 3 wire potentiometer can work.
25) Remove fault code LED driver.
26) Current meter output.
27) Standard PC/Laptop computer to do programming. No special tools needed.
28) 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, 10 to 30V (24V preferred)
- 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: 200A – 1000A, depending on the model.
- Motor Current Limit, continuous: 100A – 500A, depending on the model.
- Max Battery Current : Configurable.
2.4 Naming Regulations
The naming regulations of Kelly KHB BLDC motor controllers:
The last letter represents opto-isolated controller.
a) The eighth letter represents regeneration (0: non-regeneration, 1: with-regeneration).
b) The sixth and seventh letters represent the max current divided by 10.
c) The fourth and fifth letters represent nominal voltage divided by 10.
d) The first three letters represent Kelly’s high power brushless motor controller.
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 of KHB Controllers:
Height: 84 millimeters
Length: 286 millimeters
Figure 2: KHB mounting holes’ dimensions (dimensions in millimeters)
3.2 Connections
3.2.1 Front Panel and back panel of KHB Motor Controller:
Five metal bars in front panel and two plugs (J1, J2) in back panel are provided for connecting to the battery, motor and control signals shown as Figure 5, 6 and 9.
Figure 5: Front panel of KHB motor controller
B+: battery positive
B-: battery negative
A/U: Output A/U phase
B/V: Output B/V phase
C/W: Output C/W phase
Figure 6: Back panel of KHB motor controller
Figure 9: The connecting diagram of J1 and J2
J1 Pin Definition
1- PWR: Controller power supply (output).
2- Current meter. <200mA
3- Main contactor driver. <1A
4- Alarm: To drive reverse beeper. <200mA
5- RTN: Signal return
6- Green LED: Running indication
7- RTN: Signal return
8- Reserved
9- Boost Switch
10- CAN bus high
11- CAN bus low
12- Reserved
13- RTN: Signal return, or power supply return
14- Red LED: Fault code.
J2 Pin Definition
1- PWR: Controller power supply (input)
2- RTN: Signal return, or power supply return
3- RTN: Signal return
4- 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
9- Reverse 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.
2. Two PWR pins, J1-1 and J2-1, are internally connected. It’s recommended to use J1-1 to supply peripherals like alarm and contactor. Twist peripheral wires with PWR is the preferred for EMC. Recirculation diodes are provided in the controller to PWR for alarm and Contactor coil driver.
3. Kelly Ampmeter positive connect to 5V power supply of controller, negative to J1-2.
4. Switch to ground is active. Open switch is inactive.
3.2.2 Wiring of KHB Motor Controller
NOTE: 0-5K potentiometer can he used as throttle signal. Wire 5V and RTN to two end terminals. and wiper will output 0-5V signal.
Please securely wire B-before any other wiring. Never put contactor or break on B-.
* CAN bus is de !Elated by default.
** Thermistor is optimal item. default to KTY83-122.
*** When you connect an external LED, the LED front panel brightness sill be reduced.
Figure 11: Standard Wiring for KHB Controllers
(12V or 24V battery supply is required)
3.2.3 Communication Port
A RS232 port is provided to communicate with host computer for calibration and configuration.
Figure 12: standard RS232 Interface
3.4 Installation Check List
Before operating the vehicle, complete the following checkout procedures. Use LED code as a reference. LED codes are listed in Table 1.
Caution:
- Put the vehicle up on blocks to get the drive wheels off the ground before beginning these tests.
- Do not allow anyone to stand directly in front of or behind the vehicle during the checkout.
- Make sure both the PWR switch and the brake are off.
- Use well-insulated tools.
- Make sure the wire is connected correctly
- Turn the PWR switch on. The LED should blink, then keep on when the controller operates normally. If this does not happen, check continuity of the PWR and return.
- The fault code will be detected automatically at restarting.
- With the brake switch open, select a direction and operate the throttle. The motor should spin in the selected direction. Please verify wiring and voltage if it doesn’t operate. Also check fuse. The motor should run faster with increasing throttle. If not, refer to Table 1 LED code, and correct the fault according to the code.
- Take the vehicle off the blocks and drive it in a clear area. It should have smooth acceleration and good power.
Chapter 4 Maintenance
There are no user-serviceable parts inside the controllers. Do not attempt to open the controller, or will void warranty. However, cleaning the controller exterior periodically should be necessary.
The controller is inherently a high power device. When working with any battery powered vehicle, proper safety precautions should be taken. These include, but are not limited to, proper training, wearing eye protection, avoiding loose clothing and jewelry, and using insulated tools.
4.1 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. Be sure it is dry before reconnecting the battery.
- Make sure the connections to the bus bars are tight. Use two wrenches for this task in order to avoid stressing the bus bars; the wrenches should be well insulated.
4.2 Configuration
You can configure the controller with a host computer through RS232 or USB port.
- Use straight through RS232 cable or USB converter provided by Kelly to connect the D9 connector to a host computer. Provide >10V (either J2 pin1 or J1 pin1) to PWR. Wire power supply return to any RTN pin.
- Do not connect B+, throttle and so on. The controller may display fault code, but it doesn’t affect programming or configuration.
Download and setup the configuration software：
http://www.kellycontroller.com/support.php
Table 1: LED CODES
Green LED Codes
| LED Code | Explanation | Solution |
| Green Off | No power or not operating |
|
| Green On | Normal operation | That’s great! You got solution! |
| Green and Red LED Keep On |
|
Red LED Codes
| LED Code | Explanation | Solution | |
| 1,2 | ¤ ¤¤ | Over voltage error |
|
| 1,3 | ¤ ¤¤¤ | Low voltage error |
|
| 1,4 | ¤ ¤¤¤¤ | Over temperature warning |
|
| 2,1 | ¤¤ ¤ | Motor fails to start |
|
| 2,2 | ¤¤ ¤¤ | Internal voltage fault |
|
| 2,3 | ¤¤ ¤¤¤ | Over temperature |
|
| 2,4 | ¤¤ ¤¤¤¤ | Throttle error at power up |
|
| 3,1 | ¤¤¤ ¤ | Frequent reset |
|
| 3,2 | ¤¤¤ ¤¤ | Internal reset | Reset caused by over current, high battery voltage or low supply voltage. It is normal if occurs occasionally. |
| 3,3 | ¤¤¤ ¤¤¤ | Throttle short or open circuit when using 1-4v hall sensor throttle |
|
| 3,4 | ¤¤¤ ¤¤¤¤ | Throttle isn’t zero when try to change direction | The controller won’t change drive direction if throttle isn’t zero. Also it won’t change direction at high speed. The controller will wait throttle and speed close to zero before changing direction. |
| 4,1 | ¤¤¤¤ ¤ | Over voltage at startup or regeneration | The controller won’t drive motor if detects overvoltage at power up. It will cut back regen current or stop regen at overvoltage. You may set max voltage threshold with GUI. |
| 4, 2 | ¤¤¤¤ ¤¤ | Hall sensor signal error |
|
| 4, 3 | ¤¤¤¤ ¤¤¤ | Motor over temperature |
|
| The Red LED flashes once at power on, then keeps off for normal operation. “1, 2” means it flashed once, then flashes twice after 1 second. The time between two flashes is 0.5 second. The pause time between one error code and another error code is 2 second. | |||
Table 2: KHB Controller CAN Commands List
Version 1.1
You should specify when sending:
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 type: data frame
Frame format: standard 11 bits ID
Length: the number of data field bytes
Data field: data[0] is the command which indicates the operation.
Controller response:
ID: The controller sends data frames with ID 115, 0x73. It also can be set by configuration program.
Frame type: data frame
Length: the number of data field bytes
Data field: The controller sends one or two data frames in response.
Commands definitions
Command CCP_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 model no. E.g. 0x4B,0x42,0x4C is ‘K’ , ‘B’, ‘L’, 0x30 is ‘0’ .
INFO_MODULE_NAME constant is defined as 64.
Command CCP_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_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_Low
Description: Getting controller’s Throttle low-end dead zone. CAL_TPS_DEAD_ZONE_LOW constant is defined as 4.
Command CCP_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
Description: Getting controller’s Brake low-end dead zone. CAL_BRAKE_DEAD_ZONE_LOW constant is defined as 5.
Command CCP_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
Description: Getting controller’s Throttle high-end dead zone. CAL_TPS_DEAD_ZONE_HIGH constant is defined as 38.
Command CCP_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
Description: Getting controller’s Brake high-end dead zone. CAL_BRAKE_DEAD_ZONE_HIGH constant is defined as 39.
Command CCP_A2D_BATCH_READ1
Length 1
data[0] 0x1b
Controller response
Length 5
data[0] Brake A/D
data[1] TPS A/D
data[2] Control power 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 / 1.84. (For 120V controller).
V = Vad / 1.39. (For 144V controller).
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 ~ 5.25V.
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 ~ 5V.
Command CCP_A2D_BATCH_READ2
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 / 1.84. (For 120V controller).
V = Vad / 1.39. (For 144V controller).
2) Ia, Ib and Ic are defined as the three phase current.
Command CCP_MONITOR1
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 side FETMOS heat sink
data[5] temperature of low side FETMOS heat sink
Description: Data batch reading.
1) PWM is output duty cycle, from 0 to 100.
2) data[1] indicates enabling motor rotation or disabling. 1 – enable, 0 – disable.
3) data[2] is defined as the temperature of motor in Celsius temperature. If the temperature sensor is not connected, the controller returns 0xFF.
4) 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℃.
Command CCP_MONITOR2
Length 1
data[0] 0x37
Controller response
Length 5
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
data[3] MSB of error code
data[4] LSB of error code
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.
2） Controller error status：(data[3] << 8) | data[4],
| data[3]M | 7 | 6 | 5 | 4 | 3 | 2 | 1 | 0 | data[3]L |
| 0x44 | 0x43 | 0x42 | 0x41 | 0x34 | 0x33 | 0x32 | 0x31 | ||
| data[4]M | 7 | 6 | 5 | 4 | 3 | 2 | 1 | 0 | data[4]L |
| 0x24 | 0x23 | 0x22 | 0x21 | 0x14 | 0x13 | 0x12 | 0x11 |
if(data[3] << 8) | data[4]=0x4008,The corresponding error code is 0x43and 0x14.
Command COM_SW_ACC
Length 2
data[0] 0x42
data[0] COM_READING
Controller response
Length 1
data[0] Current throttle switch status
Description: Getting Throttle switch status, 1 – active, 0 – inactive. COM_READING constant is defined as 0.
Command COM_SW_BRK
Length 2
data[0] 0x43
data[0] COM_READING
Controller response
Length 1
data[0] Current Brake switch status
Description: Getting Brake swith status, 1 – active, 0 – inactive. COM_READING constant is defined as 0.
Command COM_SW_REV
Length 2
data[0] 0x44
data[0] COM_READING
Controller response
Length 1
data[0] Current Reverse switch status
Description: Getting Reverse swith status, 1 – active, 0 – inactive. COM_READING constant is defined as 0.
NOTICE:
- CAN bus rate should be configured to 1Mbit/s.
- 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 Us:
Kelly Controls, LLC
Home Page:
http://www.KellyController.com
E-mail:
Support@KellyController.com
Phone:
(01) 224 637 5092
Documents / Resources
 |
Kelly KHB Series High Power Brushless Motor Controller [pdf] User Manual KHB72601, KHB12151, KHB12601, KHB14201, KHB72701, KHB72101, KHB12201, KHB12801, KHB12251, KHB12301, KHB14301, KHB14401, KHB14601, KHB12401, KHB Series High Power Brushless Motor Controller, KHB Series, High Power Brushless Motor Controller, Power Brushless Motor Controller, Brushless Motor Controller, Motor Controller, Controller |
