The DMKEB Brushless Motor Controller is designed for electric bicycles, motorcycles, and scooters, offering efficient, smooth, and quiet control. It provides high starting current while strictly limiting battery current, allowing for good acceleration and hill climbing even with relatively small batteries. The controller utilizes high-power MOSFETs and PWM technology to achieve efficiencies of up to 99%. A powerful microprocessor enables comprehensive and precise control, allowing users to adjust parameters, conduct tests, and obtain diagnostic information easily.
Function Description:
The controller features extended fault detection and protection, with an LED flashing pattern indicating fault sources. It monitors battery voltage, progressively cutting back motor drive power as voltage drops until it cuts out at a preset "Low Battery Voltage" setting, and stopping operation if the battery voltage is too high. Built-in current loop and over-current protection are included, along with configurable motor temperature protection. Current is cut back at low and high temperatures to protect both the battery and the controller, with current ramping down at 90 °C case temperature and shutting down at 100 °C. During regenerative braking, the controller monitors battery recharging voltage, progressively cutting back current as battery voltage rises and cutting off regen altogether if the voltage becomes too high. The maximum reverse speed is configurable to half of the maximum forward speed.
The DMKEB controller is configurable and programmable via a host computer through RS232 or USB, with a free GUI compatible with Windows XP/2000, Windows 7, and Vista (a standard USB to RS232 converter is recommended). It provides a +5 volt output to supply various sensors, including Hall effect types. There are three switch inputs, defaulting to throttle switch, brake switch, and reversing switch, which are activated by connection to Ground. Three analog inputs (0-5V) default to throttle input, brake input, and motor temperature input.
Other features include a configurable boost switch to enable maximum output power and a configurable economy switch to limit maximum current to half. Note that Boost and Economy functions use the same pin (J2-6, brake-AN) and cannot be enabled simultaneously if J2-6 is used for brake analog regen mode. Maximum reverse power is configurable to half power. An enhanced regen brake function incorporates a novel ABS technique for powerful and smooth regeneration. A configurable 12V brake signal input can be used instead of a motor temperature sensor. An optional joystick throttle provides a bi-symmetrical 0-5V signal for both forwarding and reversing, which can be enabled or disabled in the user program (software version 0406 or above). Configurable motor over-temperature detection and protection are supported with recommended thermistors KTY84-130 or KTY83-122. Three Hall position sensor inputs are provided (open collector, pull-up provided). An optional supply voltage range of 8V-30V is available. Cruise control can be activated by holding the throttle at a certain position for 3-4 seconds (software version 0406 or above, cannot be activated in reverse). CAN Bus is not supported.
Important Technical Specifications:
- Frequency of Operation: 16.6kHz
- Standby Battery Current: < 0.5mA
- 5V Sensor Supply Current: 40mA
- Controller Supply Voltage Range: PWR, 18V to 90V
- Supply Current: PWR, 150mA
- Configurable Battery Voltage Range: B+, Max operating range: 18V to 1.25*Nominal
- 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.
- 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)
- Peak Phase Current (10 seconds): 150A-550A, depending on the model
- Continuous Phase Current Limit: 60A-200A, depending on the model
- Maximum Battery Current: Configurable
- Motor RPM: 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).
- Brake Signal: 0-5V brake signal is used to command regen current.
- Regenerative Braking: Supports three modes of regenerative braking: brake switch regen, release throttle regen, 0-5V analog signal variable regen.
- Pedal Protection: Configurable high pedal protection; the controller will not work if high throttle is detected at power on.
- Current Multiplication: Takes less current from battery, outputs more current to motor.
- Potentiometer: Easy installation; 3-wire potentiometer will work.
- Programming: Standard PC/Laptop computer is used to do programming. No special tools needed.
- User Program: Provided. Easy to use. No cost to customers.
Usage Features:
- Specially designed for electric bicycle and scooter.
- Intelligent with powerful microprocessor.
- Synchronous rectification, ultra low drop, 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.
- Battery current limiting available, doesn't affect taking off performance.
- More startup current, can get more startup speed.
- 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.
- 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.
Maintenance Features:
The DMKEB controllers contain no user-serviceable parts, and opening the controller will void the warranty. However, periodic exterior cleaning is recommended.
Cleaning Procedure:
- Remove power by disconnecting the battery, starting with the battery positive terminal.
- Discharge capacitors in the controller by connecting a load (e.g., a contactor coil or horn) across the controller's B+ and B- terminals.
- Remove dirt or corrosion from the bus bar area. Wipe down the controller with a moist rag, ensuring it is dry before reconnecting the battery.
- Ensure connections to the bus bars (if fitted) are tight. Use two well-insulated wrenches to avoid physically stressing the bus bars.
Configuration:
The controller can be configured using a host computer via an RS232 or USB port.
- Disconnect motor wiring from the controller.
- Do not connect B+, throttle, etc. The controller may display fault codes under some conditions, but this will not affect programming or configuration.
Caution during Configuration:
- Ensure the motor is disconnected before running the Configuration Software.
- The Configuration Software is regularly updated and published on the website. Always update to the latest version, uninstalling older versions first.
- Motor pole setting is grayed out in the DMKEB user program as it does not affect performance in DMKEB controllers. This setting is only used for reading eRpm of the motor via CAN Bus, which DMKEB controllers do not support.
Installation Checklist:
Before operating the vehicle, complete the following checkout procedures, using the LED codes (Table 1) as a reference.
Caution during Installation:
- Put the vehicle up on blocks to get the drive wheels off the ground before beginning tests.
- Do not allow anyone to stand directly in front of or behind the vehicle during checkout.
- Ensure the PWR switch and brake are off. Use well-insulated tools.
- Make sure all wires are connected correctly.
- Turn the PWR switch on. The Green LED should stay on steadily, and the Red LED should turn off when the controller operates normally. If not, check the continuity of the PWR and controller ground.
- Fault codes will be detected automatically at restart.
- With the brake switch open, select a direction and operate the throttle. The motor should spin in the selected direction. If not, verify wiring or voltage and the fuse. The motor should run faster with increasing throttle. If not, refer to Table 1 LED code and correct the fault.
- Take the vehicle off the blocks and drive it in a clear area. It should have smooth acceleration and good top speed.
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