1917

Item 1917

BUY ~ Electric - Controller - Kelly

Bought for Electrotor - SloMo:

KBS72121,50A,24-72V Motor Speed Controller

Two zener diodes [IN5404] [Specsheet] came with the controller but I do not know what they are intended for.

Control Box For test stand.

Thumb Throttle: The Kelly Thumb Throttle Wuxing. It is a right-hand control. It measures to an ID of 7/8" and I assume that this is for a 7/8" tube.

The wires are; red, blue and black. The resistance across the red and black is 2.42K. No resistance value is displayed between the blue and the other two terminals, even when moving the control away from the spring loaded end stop. This is probably due to the 'make contact' switch.

Twist Grip Throttle: Throttle Hall 0-5V Twist Grip(LONGMA) It is a left-hand control. It has a stated ID of 22,3mm. It measures to an ID of 7/8" and I assume that this is for a 7/8" tube.

The wires are; red, white and black. The resistance across the red and black is 1.99K. No resistance value is displayed between the blue and the other two terminals, even when moving the control away from the spring loaded end stop. This is probably due to the 'make contact' switch.

The Kelly Throttle Hall 0-5V Twist Grip(LONGMA)

Amperemeter For test stand.

72V Charge Meter For test stand. Then a second one to replace the broken one.

I only Main Contactor CZ 48VDC Coils 100Amps

1 only Main Contactor CZ 72VDC Coils 100Amps
The following items are shown on this page and on this page. They have not yet been received.

1 only ANE 100A Fuse

1 only ANE 200A Fuse

2 only ANDU Fuse Holder

1 only Fuse Holder_5*20

2 only KTY83-122 Thermistors10 only Wiring Noses 100A

KBS Controllers:

Download Kelly KBS Controllers User Manual V 1.2

Download Kelly KBS User Configuration Program Setup v1.2

Kelly KBS Controllers Configuration Program Online Demo / Help.

Information on Control by Kelly; used with Stock F & P and Hall Effect Sensor:

Videos: http://www.youtube.com/watch?v=-16TluHidqQ, http://www.youtube.com/watch?v=oyXD3daAv-c

Have bought Kelly; see; BUY ~ Control - Power Train ~ Electric - Kelly Controls

Initial Controller Settings:

Foot switch ~ Disable

Throttle Sensor Type ~ 3-wire Pot

Throttle effective starting position ~ 20% (default) ~ Then changed to 10.

Throttle effective ending position ~ 80% (default) ~ Then changed to 100.

Maximum Motor Current ~ 100%

Maximum Battery Current ~ 100%

______________________________________________________

Start-up Delay ~ 0,5 sec

Control Mode [Torque - Balanced - Speed] ~ Torque ~ Then changed to Speed. RPM was originally 20, then with changes it went up to 60.

Under Voltage ~18V

Over Voltage ~ 90V. Then changed to 55V, Changed to 75V for 6 x 12V batteries in series,

Throttle Up/Down Rate ~ 3. ~ Then changed to 10, then to 20.

Power on High Pedal Disable ~ enable

Releasing Brake High Pedal ~ Disable

______________________________________________________

Motor Top Speed ~ 100%

Half Speed in Reverse ~ Disable

Boost Function ⁽¹⁾ ~ Disable ~ Then changed to Enable. ⁽³⁾

Turbo ⁽²⁾ ~ Disable ~ Then changed to Enable. ⁽³⁾

Half Current in Reverse ~ Disable

______________________________________________________

Regeneration ~ Disable
Brake Switch ~ Disable
Releasing Throttle Starts Regen ~ Disable
Regen Current by Brake Switch On ~ 5% (lowest)
Max Regen Current ~ 20% (lowest)
Brake Sensor Type ~ No Used
Break Sensor Starting Point ~ 0%
Break Sensor Ending Point ~ 50%

______________________________________________________

Motor Temperature Sensor ~ Enable ~ Then changed to Disabled.

Controller Stop Output Temperature ~ 100C

Controller Resume Output Temperature ~ 90C

______________________________________________________

Notes re. Control settings:

The remarks on the Kelly Controller Configuration program say;

(1) Boost Function: If enabled, the controller will output max power right after Brake signal >4.2V. Or say you can wire a boost switch between Brake Input an 5V to activate it.
(2) Turbo Function: If enabled, the maximum output current will be limited to half the normal condition if Brake signal > 2V Or say you mave wire a boost switch between Brake Input and 5V to activate it.

My observation;

(3) The program will only allow one of the two to be enabled.

Previous notes re. Control settings on DIY Electric Car forum:

(1) Boost function: "The boost function supplies full 1000 amps regardless of throttle position ??? not sure how effective this will be on track but wired it up anyway,"
(2) Turbo: "These controllers find commercial use in lift trucks or booms. There the mode is used to limit travel speeds when the load is up in the air, for stability and safety."

DESIGN: Electrotor-SloMo - Control - Electric - Control Circuit - Three-phase - Overview

Hall Effect Sensor:

Bought 2 F&P Hall Effect sensors and positioning bracket.

Outside information on Improve Hall sensor rotor-position measurements Part 1 Part 2

Thermistor:

Re motor temperature. The Kelly controller has an input for motor over temperature detection and protection with recommended thermistor. Also, the temperature setting can be changed with the configuration program. Perhaps this is the way to get motor coil temperatures.

The thermistor for the Kelly controller is KTY83-122, which can be bought from Kelly for $5.00. Main Electronics says that they can get it in a weeks time. These are the specifications on the KTY83-122.

The 2 thermistors from Kelly came with 2 1K resistors. I assume that they are to be connected in series, or parrallel?.

Temperature Sensor - Motor:

Winding Thermistors

For more information see; OTHER: Electrical - Control - Temperature Sensor

RPM indicator:

Perhaps this information can come from the Hall sensors.

Torque indicator:

Need fuse and main switch for batteries.

Honeywell; http://hpsweb.honeywell.com/Cultures/en-US/Products/Instrumentation/tempsensors/default.htm

For the phasing graph see; DESIGN: Electrotor-SloMo - Control (flight & electric) - Control Circuit - Three-phase - Overview

Outside comments on the Kelly Controller KBS72121 (which we have)

----- Original Message ----- Sent: Friday, May 28, 2010 1:40 PM Subject: Kelly Controller

KBS72120, 72V for BMC V3 motor
by John Cox Date Added: Sunday 14 March, 2010
	Only Torque mode works, not speed mode or balanced mode. Also, this is really a 48v24a controller, not 72v48a controller. At 72v. controller gets very hot very fast with BMC V3, also runs very slow to start. When I reported this, Kelly recommended to not run at 48v not 72v, so this is really a 48v controller. At 48v, this controller is slow, and gets very hot. Kelly recommended to run at 50% current, so this is really a 24a not 48a controller. Even at 50% curent, this controller runs too hot and too inefficeintly to use, so it is on my scrap pile. The BMC 48v50a controller runs cool, and runs the BMC V3 motor much faster for less money. The phase wires on the motor must be upgraded to 10ga (I used 8ga) prior to testing either controller. Rating: [1 of 5 Stars!]

BMC V3 is a high power, high torque brushless hub motor that handles 1000 watts continuously

Concerns:

Deceleration:

Perhaps the Kelly controller does not allow proper deceleration is because it was primarily designed for regeneration. It would be interesting to put the controller into Regeneration mode and see what happens.

Last Revised: June 9, 2011