Koors40 Brushed Speed Controller

I. Introduction

The Koors40 Brushed Speed Controller is designed to provide a lower cost, precise control for brushed DC motors. This manual will guide you through the operation, features, and basic troubleshooting of the device. This speed controller incorporates protection features such as overcurrent protection and thermal management for robust and reliable operation.
NOTE: In the servo world the input control signal is referred to as PWM (Pulse Width Modulation). For consistency, this manual will use the PWM abbreviation. The technically correct abbreviation for this type of signal is PPM (Pulse-position Modulation).

II. Key Features

Protection Features

• Reverse Polarity Protection: Prevents damage if the power supply is connected backwards. No power is passed to the speed controller.
• PWM Ground Protection:
• Protects against input power ground loss
• Current limit fuse causes motor to emit chirps
• This prevents motor current going through PWM ground, which would otherwise cause damage
• Overcurrent Protection: Derates the PWM signal if the current exceeds 65A for 3 seconds
• Over Temperature Protection: Automatically shuts down at 212F (100C)

Operating Modes

• Brake Mode: Brings the motor to a quick stop
• Coast Mode: Allows the motor to freely spin down

III. Operation

Connection Setup

1. Connect 6V-18V power source (observe polarity)
2. Connect brushed DC motor to output terminals
3. Connect PWM control signal to input terminal
4. To toggle between Coast and Brake mode, carefully press the Coast/Brake button with something like a toothpick

IV. LED Status Indicators

The Koors40 features an integrated LED that provides visual feedback on the controller's operational status.

State	Condition	Signal	LED Indicator	Visual	Description
No PWM Input	Brake	No Signal	Blinking Blue		Controller is in Brake Mode and does not have a valid signal
PWM Input	Brake	Valid Signal	Solid Blue		Controller is in Brake Mode and getting a valid neutral signal
No PWM Input	Coast	No Signal	Blinking Yellow		Controller is in Coast Mode and does not have a valid signal
PWM Input	Coast	Valid Signal	Solid Yellow		Controller is in Coast Mode with a valid signal
Partial Forward	Running	PWM > 1500us	Blinking Green		Motor is running forward at partial power
Full Forward	Running	PWM = 2000us	Fast Blinking Green		Motor is running forward at full power
Partial Reverse	Running	PWM < 1500us	Blinking Red		Motor is running in reverse at partial power
Full Reverse	Running	PWM = 1000us	Fast Blinking Red		Motor is running in reverse at full power
Fault	Gate Driver/Thermal	Error	Slow Blinking Orange/Cyan		Gate driver fault, no power, or thermal shutdown (212°F)
Fault	Overcurrent	Error	Blinking Red/Orange		Overcurrent fault (>65A for 3s)

V. Safety Precautions

Follow these safety guidelines to ensure safe operation and prevent damage to the Koors40 Brushed Speed Controller.

• Proper Wiring: Ensure correct polarity when connecting power and PWM for proper operation.
• Voltage Limits: Do not exceed the 18V input voltage limit to prevent damage.
• Environmental Conditions: Do not expose the controller to water, conductive debris, or extreme temperatures.
• Emergency Shutoff: Always have a power switch or fuse in place to quickly disconnect power in case of malfunction.
• Overheating: If the controller internal reaches 212°F (100°C), it will shut go into thermal shutdown. This can happen if operating at 40A continuously (~4min). See III. LED Status Indicators. Reduce motor load and allow it to cool before restarting.
• PWM Signal Integrity: In electrically noisy environments, the use of shielded cables for PWM input is recommended to prevent signal noise and erratic motor behavior.

VI. Troubleshooting

If you encounter any issues while using the Koors40 Brushed Speed Controller, refer to this guide for possible causes and solutions.