Kelly Controller - FAQs
FREQUENTLY ASKED QUESTIONS
THE DIFFERENCE BETWEEN KLS-8080I AND KLS-8080IPS.
KLS-8080I is designed for the motor with common three hall sensors.
KLS-8080IPS is designed for the motor with Sine/Cosine speed sensors.
You may check more details in configuration part of KLS8080I/IPS user manual.
When speed sensor type is set at 4 for linear feedback sensor(sin/cosin speed sensor),you may use KLS-8080IPS controller.
For example,Mars 1115 motor is one of kinds of these motors.You need to use KLS-8080IPS controller to match Mars 1115 motor.
There are +5V,GND,Sin and Cosin I/O port on speed sensors from this motor.
THE CAN BUS CAN BE CAN2.0A(1MBPS) OR J1939(250KBPS) PROTOCOL.
Kelly trapezoidal wave controller KBL/KHB/KDHE/HPM can support CAN2.0A(1Mbps) or J1939(250Kbps) protocol.
CAN bus is an optional function for these controllers.By default,there is no CAN bus included in the controller if customers don't pay it.
Moreover the protocol is CAN2.0A type by default if you pay the CAN bus function.
Kelly Sinusoidal wave controller KLS-D/KLS-8080I/IPS supports Broadcast type CAN bus which is based on SAEJ1939 and CAN2.0B protocol.
By default,CAN bus is not included in KLS-D controller if customers don't choose the check-box for CAN bus when they place the order.
KLS-8080I/IPS controller includes Broadcast CAN bus function by default.
Customers can download Broadcast CAN protocol from the website.
THE NEW BOX IS DEDICATED TO THE KDZ/KDC/PM ASSEMBLY INCLUDING THE SHUNT INSIDE.
The new box is dedicated to the KDZ/KDC/PM assembly including the shunt inside.But It is only useful for the assemblies below,nothing else.
1.KDZ/KDC Sep/ex motor controller assembly
2.KDZ/KDC Series wound motor/PM brushed motor controller assembly without reversing contactor
3.PM brushed motor controller assembly
On the other hand,we will publish one more new box for other assemblies according to the requirements in the near future.
This new box provides friendly I/O ports for customers to hook up the system between the motor,battery pack and the assembly.It can protect the assembly against the dirty or rain.
THE CHARACTERISTICS OF KELLY KSL SENSORLESS BLDC CONTROLLER:
1. KSL is designed for fan,pump,compressor.It is not suitable for electric vehicles such as motorcycle,scooter or moped project.
2. KSL will drive the motor with a certain speed once power is on.You can not stop it unless power is off.
3. You can not change its direction unless the power is off also.
4. You may apply a higher throttle position for the controller before power is on.It will be easy for the controller to start the motor.
5. It only supports 1,7000eRPM so far.
KELLY 12V DC MOTOR CONTROLLERS.
All 24V controllers can work with 12V-24V nominal batteries, or 8-30V absolute voltage. If you need 12V controllers, please order Kelly 24V controllers.
HOW TO CHOOSE A SUITABLE CONTROLLER FOR THE MOTOR?
Usually the performance will be optimized if the power of the controller is 2.0-3.0 times of the motor's. Please take this point as reference when place an order online.
MOTOR CURRENT VS. BATTERY CURRENT, AND BATTERY CURRENT LIMIT.
HOW TO CALCULATE MOTOR CURRENT AND BATTERY CURRENT?
The controller current rating is the motor current. Basically motor current=max motor current *percentage, battery current=motor current*percentage.
For example, KEB72450, we set Max Motor Current and Max Battery Current to 80% and 60% respectively. The motor current will be 150A*80%=120A peak. The battery current will be 120A*60%=72A.
STICK SHIFT THROTTLE
Usually it is used on electric boat.You can drive the motor on backward and forward without installing reversing switch.It is just a software function,which is none of business with external hardware.By default,2.5V is zero speed position,2.4V-2.6V is throttle dead zone,2.6V-5.0V is for forward,2.4V-0V is for backward.You can adjust the throttle dead zone in GUI.
HOW TO ADJUST HALL TIMING?
Please note the EMF is differential of two motor terminals. Basically EMF zero crossing should align with hall edge.
The controller doesn't detect EMF zero crossing. It just reads hall, and assuming the EMF align with it.
Please download the example timing Phase vs Hall.
Hall Phase timing 60 degrees
Hall Phase timing 120 degrees
HOW DOES REGEN WORKS?
Kelly regen controllers can boost motor voltage (EMF) to battery voltage, and charge up battery. It takes energy from motor so will slow down the motor. Controller will check overvoltage limit as doing regen. As battery voltage approaching the limit, it will reduce regen. It will stop regen if reached the limit.
On the other hand, the controller can't buck down motor voltage. If motor running at too high speed and motor voltage is higher than battery voltage, it will charge battery automatically. That can hurt controller and battery if energy is too high.
Usually regen requires stable field. So PM, sep-ex, BLDC and PMAC motors are ideal to do regen.
HOW "RELEASE THROTTLE REGEN" WORKS?
The controller will start regen as soon as throttle released. Vehicle will slow down because of braking effect of the regen. Only recommended for special application like riding on hilling or rolling area. No recommended for road vehicle because you will lose "free running".
Continuous adjustable regen braking with 0-5V signal is recommended for road vehicle.
THREE KINDS OF REGEN MODES.
"Releasing Throttle Starts Regen" means starts regen when the throttle is released.
"Brake Switch Regen" means starts regen as soon as the brake switch is activated to RTN after the throttle is released.
"0-5V Signal Regen" means the regen can be adjusted by varying the signal. You must install 0-5V brake sensor.
By default the controller will work with brake switch regen mode. You couldn't use three regen modes at the same time. You need to disable other two modes.
THREE KINDS OF CONTROL MODES.
Speed mode, torque mode and balanced mode.
Customers can configure it other than KD/KDS controller in GUI. KD/KDS controller can only work with torque mode.
The controller will output voltage to motor proportional to throttle if under speed control mode. It will output current if under torque mode. The balanced mode is between them.
The 0-5V signal from either 0-5K pot or 0-5V hall active throttle can be accepted. Normal is 5K,2K-20K can be used.
The motor will reach top speed quickly working under torque mode if with empty load.
SPECIAL SETTING FOR THROTTLE TYPE ON KD CONTROLLERS.
The controller KD can work with either 2-wire 0-5K pot or 3-wire pot and hall active throttle. By default, the controller works with 2-wire 0-5K pot, the throttle type is 0-5K in GUI. If you want to install 3-wire 0-5K pot or Hall active throttle on the back face panel of the controller, please choose 0-5V for the throttle type in GUI. Otherwise the controller won't response the throttle signal.
WHAT DOES CURRENT MULTIPLICATION MEAN?
The controller does current multiplication. You can limit the battery current,but still get higher current to the motor at low speed.
WHAT'S BLDC HIGH SPEED MODEL AND ULTRA HIGH SPEED MODEL DIFFER FROM STANDARD MODEL?
32-bit microprocessor, higher PWM frequency.
Standard model: 16.6KHz, 40,000 eRPM.
High speed model: 33KHz, 70,000 eRPM.
Ultra high speed model: 100KHz, 100,000 eRPM.
eRPM=Mechanical RPM*Pole pairs.
It does generate more heat because of higher switching frequency.
WHEN WILL HIGH SPEED MOTOR OPTION OR ULTRA HIGH SPEED MOTOR OPTION BE NECESSARY FOR THE MOTOR?
Please note high speed motor option is only useful for high speed motor.
The standard controller can support 40,000eRPM.
What is the criterion for high speed motor?
When eRPM of the motor is above 40,000, we can call it high speed motor for Kelly controller.
The high speed motor option doesn't mean it will push the motor to get a higher speed.
High speed motor option means that it is capable of catching the hall switching time of high speed motor.
If the motor is 40,000eRPM below, the standard controller can tackle the switching signal from hall sensor.
The motor will run properly.
That is why we don't add high speed motor option to the controller for low speed motor, which is not used to increase RPM.
The speed is the inherent characteristic of the motor. We can not change it.
Just like resistance is the inherent characteristic of the resistor.
Similarly Ultra high speed motor option is only useful for ultra high speed motor(70KeRPM-100KeRPM).
WHAT "E" SUFFIX TO KDS/KBS CONTROLLER MEANS?
"E" model gets higher efficiency and higher continuous current. It generates 30% to 50% less heat comparing with standard model.
SOME TIPS ABOUT INSTALLING KELLY USER PROGRAM.
Make sure PWR switch is turned on. We suggest do not install user program in C disk of your computer.
XP or Vista operation system is preferred.
Some protection software will not be compatible with the user program.
USB to RS232 converter is necessary for building the communication between the computer and controller. Kelly RS232 converter is also required only for KD, KDS, KDHD controllers.
PROGRAMMING THE CONTROLLERS.
If you only want to program the controller, B+ and B- can be disconnected. You only need to connect the power to J2 pin 1 and J2 pin 2 or PWR vs GND/RTN. You can not try to connect the controller to the computer while the motor is running. Restart the power supply can obtain the change results.
HOW TO CHECK IF CONTROLLER WAS DAMAGED ?
Firstly, you should see Green Light solid ON, Red Light flashing or off if the controller is powered.
Then, please measure how much is J2 pin7 or 5V out. You may measure the resistance of the controller, unpowered, from B+ to Phase A, B, C, and from Phase A, B, C to B- if it is a brushless motor controller, measure from B+ to M, and from M to B- if brushed motor controller.Please swap Red probe and Black probe on the terminals when you measure the resistance to avoid the discharge from the capacitors. You may remove the controller from the motor prior to measure the resistance. You should see the resistance gradually up to Kohm rating. Otherwise the controller got damaged.
We usually spec 8-30V for the power supply of the isolated controller, which must be separated from main battery pack. Basically B+/B-/M or B+/B-/A/B/C those high current high voltage terminals are in one group. They are isolated from everything. B- only can be connected to main battery pack minus, nothing else.
Kelly brushless controllers(KBL, KEB, KBS, HP,KHB series), KD controllers with field, KDC controllers with field and PM controllers can do electric reversing by themselves. They can change polarity of drive to the motor, so the motor can change direction. You still need to give the controller a small switch signal, commanding the controller to do that. The controllers can do that very quick, without wearing or tearing. Other series controllers can't change polarity of output. You need an external reversing contactor to do that.
Many types of hall sensors can work with our controller. The operation voltage 3-20V can be used. Kelly controller can provide 5V out supply. It is capable of detecting the signal value from the hall. The range 2.5V-4.5V is for high level. The remaining is for low level. Min datas: 0.7V-1.0V(low). Max datas: 4.0V-4.5V(high).
Waterproof controllers are IP65. Normal version is IP44.