Brushless-KBL-bldc-motor-controller-user-manual
Brushless-KBL-bldc-motor-controller-user-manual
Brushless Motor
Controller User’s Manual
Devices Supported:
KBL24101X KBL48101X KBL72101X KBL96251
KBL24221X KBL48221X KBL72221X
KBL24301X KBL48301X KBL72301X
KBL24401X KBL48401E KBL72401E
KBL48501E KBL72501E
Rev.3.4
Feb. 2023
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Brushless Motor Controller User’s Manual V 3.4
Contents
Chapter 1 Introduction ................................................................................. 2
1.1 Overview ........................................................................................... 2
Chapter 2 Features and Specifications ........................................................ 3
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Brushless Motor Controller User’s Manual V 3.4
Chapter 1 Introduction
1.1 Overview
This manual introduces the Brushless BLDC 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 Brushless Controls, LLC.
Brushless‟s programmable motor controllers provide efficient, smooth and quiet controls for
golf carts, go-carts, electric motorcycles, forklifts, hybrid vehicles, electric vehicles and electric
boats, as well as industrial motor speed or torque control. It uses high power MOSFET‟s and,
PWM to achieve efficiencies of up to 99% in most cases. A 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.
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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!).
2.2 Features
1) Intelligence with powerful microprocessor.
2) Synchronous rectification, ultra low drop and fast PWM to achieve very high efficiency.
3) Electronic reversing.
4) Voltage monitoring on 3 motor phases, bus, and power supply.
5) Voltage monitoring on voltage source 12V and 5V.
6) Current sense on all 3 motor phases.
7) Current control loop.
8) Hardware over current protection.
9) Hardware over voltage protection.
10) Support torque mode, speed mode, and balanced mode operation.
11) Configurable limit for motor current and battery current.
12) Low EMC.
13) LED fault code.
14) Battery protection: current cutback, warning and shutdown at configurable high and low
battery voltage.
15) Rugged aluminum housing for maximum heat dissipation and harsh environment.
16) Rugged high current terminals, and rugged aviation connectors for small signal.
17) Thermal protection: current cut back, warning and shutdown at high temperature.
18) Configurable 60 degree or 120 degree hall position sensors.
19) 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).
20) Support three modes of regenerative braking: brake switch regen, release throttle regen,
0-5V analog signal variable regen.
21) Configurable high pedal protection: the controller will not work if high throttle is detected at
power on.
22) Current multiplication: Take less current from battery, output more current to motor.
23) Easy installation: 3 wire potentiometer can work.
24) Remote fault code LED driver.
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2.3 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 86V for
KBL controllers rated equal or lower than 72V. 18V to 115V for 96V controllers.
•Configurable battery voltage range, B+.
•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: 0ﹾC to 50 ﹾC (controller case temperature).
•Operating Temperature Range:-30ﹾC to 90 ﹾC,100ﹾC shutdown(controller case temperature).
•Boost Current, 10 seconds: 150A-550A, depending on the model.
•Max Battery Current : Configurable.
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Height: 62 millimeters
Figure 1: KBL mounting holes‟ dimensions (dimensions in millimeters)
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Brushless Motor Controller User’s Manual V 3.4
Height: 84 millimeters
Figure 2: KBL-E mounting holes‟ dimensions (dimensions in millimeters)
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3.2 Connections
3.2.1 Front Panel of BLDC Motor Controller:
Five metal bars and two plugs (J1, J2) are provided for connecting to the battery, motor and
control signals in the front of the controller shown as Figure 3, 4 and 5.
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Brushless Motor Controller User’s Manual V 3.4
J1 Pin Definition
1- 12V 30mA.Only can be used for switch signals.
2- Current meter. <200mA
3- Main contactor driver. <2A
4- Alarm: To drive reverse beeper. <200mA
5- RTN: Signal return
6- Green LED: Running indication
7- RTN: Signal return
8- RS232 receiver
9- RS232 transmitter
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. 12V high-level brake and 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. Reversing switch input
10. Brake switch input
11. Hall phase C
12. Hall phase B
13. Hall phase A
14. RTN: Signal return
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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.
3. Brushless Ammeter positive connect to 5V power supply of controller, negative to J1-2.
4. 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.
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Figure 6: Standard Wiring for Controllers Rated Equal or Lower Than 120V.
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Brushless Motor Controller User’s Manual V 3.4
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 the PWR switch and the brake is off
• Use well-insulated tools.
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Chapter 4 Maintenance
There are no user-serviceable parts inside the controllers. Do not attempt to open the
controller as this will void your warranty. However, periodic, exterior cleaning of the controller
should be carried out.
The controller is a high powered device. When working with any battery powered vehicle,
proper safety precautions should be taken that include, but are not limited to, proper training,
wearing eye protection, avoidance of loose clothing, hair and jewelry. Always use 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. Make sure that the controller is dry before reconnecting the battery.
• Make sure the connections to the bus bars, if fitted, are tight. To avoid physically stressing
the bus bars use two, well-insulated wrenches.
4.2 Configuration
You can configure the controller with a host computer through either an RS232 or USB port.
Disconnect motor wiring from controller.
Do not connect B+, throttle and so on. The controller may display fault code in some
conditions, but it doesn't affect programming or configuration.
Use straight through RS232 cable or USB converter provided by Brushless to connect to a
host computer. Provide >+18V to PWR(for a 24V controller, provide >+8V). Wire power
supply return(supply negative) to any RTN pin.
Caution:
•Make certain that the motor is disconnected before trying to run the Configuration
Software!
•Configuration software will be regularly updated and published on the website. Please
Update your Configuration Software regularly. You must uninstall the older version
before updating.
•Motor pole setting is nothing to do with performance in KEB controller, so motor pole
setting is grayed in KEB user program.This setting is only used for reading eRpm of
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Brushless Motor Controller User’s Manual V 3.4
motor via CAN Bus.But KEB controller can’t support CAN Bus at all.
•Motor pole setting is only available for KBL controller with CAN Bus.It’s supposed to
be used to read eRpm of motor via CAN Bus.CAN bus is not included in the controller
by default if customers do not specify it before ordering.
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Brushless Motor Controller User’s Manual V 3.4
3,2 ¤¤¤ ¤¤ Internal reset May be caused by some transient fault condition like
a temporary over-current, momentarily high or low
battery voltage. This can happen during normal
operation.
3,3 ¤¤¤ ¤¤¤ Hall throttle is open When the throttle is repaired, a restart will clear the
or short-circuit fault.
3,4 ¤¤¤ ¤¤¤¤ Non-zero throttle on Controller won‟t allow a direction change unless the
direction change throttle or speed is at zero. Fault clears when throttle
is released.
4,1 ¤¤¤¤ ¤ Regen or Start-up Motor drive is disabled if an over-voltage is detected
over-voltage at start-up or during regen. The voltage threshold
detection level is set during configuration.
4, 2 ¤¤¤¤ ¤¤ Hall sensor error 1. Incorrect or loose wiring or a damaged hall
sensor.
2. Also be caused by incorrect hall angle
configuration (60 degree or 120 degree).
4, 3 ¤¤¤¤ ¤¤¤ Motor Motor temperature has exceeded the configured
over-temperature maximum. The controller will shut down until the
motor temperature cools down.
4, 4 ¤¤¤¤ ¤¤¤¤ Motor locked rotor When in locked rotor condition, the max output phase
current of the motor will be limited to 90% of previous
current. Once this problem disappears, the fault will
clear and the max output phase current will return to
normal.
The Red LED flashes once at power on as a confidence check and then normally stays
Off. “1, 2” means the Red flashes once and after a second pause, flashes twice. The pause
time between multiple flash code groups is two seconds.
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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 a data frame 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
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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
Desccription: Getting controller‟s Throttle high-end dead zone. CAL_TPS_DEAD_ZONE_HIGH
constant is defined as 5. The maximum value of Throttle is 200. If the value of Throttle High-end Dead
Zone is 160, indicating 80% high-end dead zone. (160/200 is 80%.)
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
Desccription: Getting controller‟s Brake low-end dead zone. CAL_BRAKE_DEAD_ZONE_LOW
constant is defined as 38. The maximum value of Brake is 100. If the value of Brake Low-end Dead Zone
is 20, indicating 20% low-end dead zone. (20/100 is 20%.)
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
Desccription: Getting controller‟s Brake high-end dead zone. CAL_BRAKE_DEAD_ZONE_HIGH
constant is defined as 39. The maximum value of Brake is 100. If the value of Brake High-end Dead
Zone is 80, indicating 80% high-end dead zone. (80/100 is 80%.)
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] Operation voltage A/D
data[3] Vs A/D
data[4] B+ A/D
Description: Data batch reading.
1) For operation voltage, B+, A/D value and voltage mapping relation is:
V = Vad / 4.06. (For 24V,36V,48V controller);
V = Vad / 2.71. (For 72V controller);
V = Vad / 1.84. (For 120V 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
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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 / 4.06. (For 24V,36V,48V controller);
V = Vad / 2.71. (For 72V controller);
V = Vad / 1.84. (For 120V 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 3
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
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.
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
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Brushless Motor Controller User’s Manual V 3.4
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:
1.CAN bus rate should be configured to 1Mbit/s.
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