Kelly KDC Series/PM Motor Controller User`s Manual
Contents
1. AC Vulg gt ATIP IIPAN tI NIN I H pausa CD TND IE TN Wl H NVO 0I HNVO XLCECSN 6 XLTETXA XATETSA 8 34 XYTETXA NIN L IR 9 NIN BZN SA _ UY b suey cc uci D jeuondo AT gt YUlc gt CAT WD ax Diode 200V 3A co Key Switch IOJOJA xq das Figure 10 Sep Ex Motor Controller Standard Wiring 15 V 3 3 Kelly KDC Series PM Motor Controller User s Manual Precharge Resistor 2KQ 20W L D 120V Battery Pack Main Contactor D OST 8A LM 0 MeJap W jeuondo sr IOJSULIYL se paonpal aq JM SSI SIG pued juo AIT TT JELI ue Jp uu03 NO WAJAN ynvzap Aq payemdodap st snq NFD g o MY3 1G 10 10 9 00 jnd WAIN SULT 191J0 Kuu a10Jaq g ATW Ajamdas ISVIL qeusrs x 0 dio qr r d pue speururm2 pua 0443 0 NTY PUL AS ITAA TRUSTS IOT se pasn aq UL t utlenu od MN 0 LLON Ac Vuls CAT Pea x HMS MASM gu 7 XLCECXN XYTETXU AE e en an 2256 Diode 200V 3A NIN TUD 9 NIN uey b ppUm N Djauduy c WMd I S If 37 W H 9 idi Iep d LIA AS 0 3pmodm AS 0 22 JMS J YOLOW x3 d s ma W euondo AC Vuls gt CT MALO lt2. valid brake value O 100 PGN 0x017D00 Parameters switch status Description 3 bytes data 0 data 2 are defined as current Throttle switch status Brake switch status and Reverse swith status 1 active O inactive PGN 0x017E00 Parameters A D value of voltage and current Description 6 bytes definition as following data 0 B A D 26 Kelly KDC Series PM Motor Controller User s Manual V 3 3 data 1 Ib A D data 2 Ic A D data 3 BEMF AD data 4 Va A D data 5 Vc A D For B Va BEMF AD 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 A D value and voltage mapping relation is 120 134 mapping to 4 75 5 25V Ib is defined as drive current AD and lc is defined as regeneration current AD BEMF AD is defined as back EMF AD If you are using the controllers which are specially designed for Separately excited motor so that Va is defined as reverse excited field voltage AD and Vc is defined as forward excited field voltage AD otherwise Va and Vc are returned OxFF PGN 0x017F00 Parameters monitor Description 2 bytes data 0 PWM is output duty cycle from 0 to 100 data 1 current accounts for percent of the rated current of controller The Message for Command When receiving command node will execute corresponding operation E g When receiving command with PGNOx017600 controller will
3. 3bits limit 0 7 Vehicle System Instance Fields 0 4bits limit 0 15 Vehicle System Fields O 7 bits limit 0 127 Reserved Fields Function Fields 25 1 bit 0 0 8 bits limit 0 255 Kelly KDC Series PM Motor Controller User s Manual V 3 3 Function Instance Fields 0 5bits limit 0 31 ECU Instance Fields O 3 bits limit 0 7 Manufacturer Code Fields 0 11 bits limit 0 2047 Identity Number Fields 21 bits limit 0 2097151 The message for Request PGN R is 0 DP is 0 PF is 234 PS is specific or global destination address Data Field is the requested Parameter Group Number PGN If the node support the requested parameter group it will send this parameter group E g Acontroller whose SA is 0x80 receives a message for Request PGN which is 0x18 EA 80 81 00 78 01 It means the node whose SA is 0x81 requests the Parameter Group with PGNOx017800 and P of this message is 6 If our controller supports this Parameter Group the response to the request is 0x19 78 81 80 data 0 data 7 whose P is 6 R is 0 DP is 1 PF is 0x78 DA is 0x81 SA is 0x80 data 0 data 7 are the value of Parameters Now the PGNs supported by our controller are as follows PGN 0x017800 Parameters controller s model Description Controller s model in ASCII format 8 bytes E g If the model of controller is KBL72301 it would send a message with 8 bytes which are data 0 data 7 namely 0x31 0x30 0x33 0x32 0x37 0x4
4. Figure 11 120V Sep Ex Motor Controller Standard Wiring 16 Kelly KDC Series PM Motor Controller User s Manual V 3 3 3 2 5 Communication Port A RS222 port of controller is provided to communicate with host computer for calibration and configuration Ol bb ice O O O 9 O O Figure 12 standard RS232 interface 3 3 Installation Checklist Before operating the vehicle complete the following checkout procedures Use LED code as a reference as listed in Table 1 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 Make sure the wire is connected correctly Turn the PWR switch on The Green LED stay on steadily and Red LED turns off when the controller operates normally If this does not happen check continuity of the PWR and controller ground The fault code will be detected automatically at restart 17 With the brake switch open select a direction and operate the throttle The motor should spin in the selected direction Verify wiring or voltage and the fuse if it does not The motor should run faster with increasing throttle If not refer to the Table 1 LED code and correct the fault as determined by the fault code Take the vehicle off the blocks and drive it in a clear ar
5. 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 14 V 3 3 Kelly KDC Series PM Motor Controller User s Manual 3 2 4 Standard Wiring of KDC Sep Ex Motor Controller Precharge Resistor 1 KO 10W D Battery Main Contactor O T FSALM 0 ymugop ura peuondo sr 10jsruriaq xxx paonpai aq JIM ssy fuq pued juo GAT eq TT LTI ue j2auuo no uada lt lt amuygep Aq pajemdodop st snq NY g uo xea1q 10 10 283u00 Md AN Sut 1210 Kuu a 10Jaq g AM A 3In285 su lq euis 4c 0 1ndjno gra tada pure speururi3 pua ory 0 N TM pue AS MAA TRUSTS opo SE pasn aq UL 12j2uenuajod xs 0 lt ALON I TIIMS IASA a I 9D1O4UI AS O Teped 481g ASO I NIN T pause TI paunsay II Pau ormsawg 6 MS ASIMIY 8 MSODIA L nding AS
6. execute the operation of writing throttle to change the speed of motor If P of this command is 3 R is 0 DP is 1 PF is 0x76 DA is 0x80 SA is 0x81 data 0 is 0x10 the message for this command is OxOD 76 80 81 10 After finishing the command of writing throttle with 0x10 the controller with SAOx80 will send a ACK message to the global address showing this command can be executed ACK 0x18 E8 FF80 00FFFFfFF FF 00 7601 NACK 0x18 EB FF80 01 FF FF FF FF 00 76 01 P is 6 R is 0 DP is O PF is OxE8 DA is OxFF SA is 0x80 That data 0 of the last eight bytes is 0 indicates ACK That data 0 is 1 indicates NACK data 5 data 7 of the last eight bytes are the PGNO 2 of requested message Now the commands supported by our controller are as follows NOTICE CAN bus rate should be configured to 250Kbit s The controller will make a response only if the message received is for address claimed the Request PGN message the command of writing TPSx or BRAKEx Contact Us Kelly Controls LLC Home Page http www kellycontroller com E mail support kellycontroller com Phone 01 224 637 5092 27
7. the motor control circuitry HIGH CURRENT ARCS Electric vehicle batteries can supply very high power and arcs can occur if they are short circuit Always turn off the battery circuit before working on the motor control circuit Wear safety glasses and use properly insulated tools to prevent short circuit Kelly KDC Series PM Motor Controller User s Manual V 3 3 POE eee m m rn u Y E Sy 2 RS en 130 14 Height 62 millimeters Figure 1 mounting holes dimensions dimensions in millimeters Kelly KDC Series PM Motor Controller User s Manual V 3 3 3 2 Connections 3 2 1 Front Panel of KDC Series or PM Motor Controller Three 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 2 Figure 2 Front panel of KDC motor controller B M battery positive and armature positive B battery negative M armature negative J1 Pin Definition 1 PWR Controller power supply output 2 Kelly Current meter lt 200mA 3 Main contactor driver lt 2A 4 Alarm To drive reverse beeper lt 200mA 5 RTN Signal return 6 Green LED Running indication 7T RTN Signal return 8 RS232 receiver Figure 3 The connecting 9 RS232 transmitter diagram of J1 and J2 10 CAN bus high Optional 11 CAN bus low Optional Kelly KDC Series PM Motor Controller User s Manual V 3 3 12 Reserved 1
8. wiring from controller Do not connect B throttle and so on The controller may display fault code in some conditotions but it doesn t affect programming or configuration Use a straight through RS232 cable or Standard USB To RS232 Converter provided by Kelly to connect to a host computer Provide gt 18V to PWR either J2 pint or J1 pint Wire power supply return to any RTN pin Download the free configuration software from http www kellycontroller com support php 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 18 Kelly KDC Series PM Motor Controller User s Manual Table 1 LED CODES LED Code Explanation Solution Green MN No power or 1 Check if all wires are correct Off switched off 2 Check fuse and power supply Green Normal operation That s great You got solution On 1 2 n nu Over voltage error 1 Battery voltage is too high for the controller Check battery volts and configuration 2 Regeneration over voltage Controller will have cut back or stopped regen 3 This only accurate to 2 upon Overvoltage setting 1 3 a nun Low voltage error 1 The controller will clear after 5 seconds if battery volts returns t
9. 3 0x44 0x4B PGN 0x017900 Parameters software version Description It is also defined as the controller s version BCD alike format storage data 0 data 1 two bytes E g If data 0 data 7 are 0x02 0x03 OxFF OxFF OxFF OxFF OxFF OxFF it should be parsed to ASCII characters 0 3 0 2 as the software version PGN 0x017A00 Parameters pedals dead zone Description 4 bytes data 0 data 3 are respectively defined as Throttle Low end Dead Zone Throttle High end Dead Zone Brake Low end Dead Zone and Brake High end Dead Zone of the controller The maximum value of Throttle and Brake are 200 and 100 If the value of Throttle Low end Dead Zone is 40 indicating 20 dead zone 40 200 is 20 PGN 0x017B00 Parameters temperature and battery voltage Description 5 bytes in Celsius temperature data 0 data 3 are defined as motor temperature controller temperature temperature of high side FETMOS heat sink and temperature of low side FETMOS heat sink data 0 is motor temperature The controller returns OxFF if the temperature sensor is not connected data 1 data 3 are defined as controller inside temperature in Celsius temperature The value of data 2 and data 3 are inaccurate below 30 C data 4 is defined as battery voltage PGN 0x017C00 Parameters valid value of throttle and brake Description 2 bytes data 0 data 1 are defined as TPSx and BRAKEx TPSx valid throttle value 0 200 BRAKEx
10. 3 RTN Signal return or power supply ground 14 Red LED Fault code J2 Pin Definition 1 PWR Controller power supply input 2 RTN Signal return or power supply ground 3 RTN Signal return 4 12V high level brake and motor temperature input Demand use KTY84 130 Silicon temperature sensors 5 Throttle analog input 0 5V 6 Brake analog input 0 5V 7 5V 5V supply output lt 40mA 8 Micro SW Throttle switch input 9 Reversing switch input 10 Brake switch input 11 Reserved 12 Reserved 13 Reserved 14 RTN Signal return 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 Kelly 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 controll
11. 4 0x04 21 Kelly KDC Series PM Motor Controller User s Manual V 3 3 Command CCP_FLASH_READ Length 3 data 0 OxF2 data 1 CAL LOWTPS DEAD ZONE data 2 1 Controller response Length 1 data 0 TPS Low Dead Zone Desccription Getting controllers Throttle low end dead zone CAL TPS LOW DEAD ZONE constant is defined as 5 0x05 Command CCP FLASH READ Length 3 data 0 OxF2 data 1 CAL BRAKE HIGH DEAD ZONE data 2 1 Controller response Length 1 data 0 Brake_High_Dead_Zone Desccription Getting controllers Brake high end dead zone CAL_BRAKE_DEAD_ZONE_HIGH constant is defined as 47 0x2F Command CCP_FLASH_READ Length 3 data 0 OxF2 data 1 CAL BRAKE LOW DEAD ZONE data 2 1 Controller response Length 1 data 0 Brake Low Dead Zone Desccription Getting controller s Brake low end dead zone CAL BRAKE DEAD ZONE LOW constant is defined as 48 0x30 Commend CCP FLASH READ Length 3 data 0 OxF2 data 1 CAL F enable data 2 1 Controller response Length 1 data 0 Enable or disable Exciting Field and Field Mode Description Getting controller s exciting field enabled or disabled and field mode CAL F enable constant is defined as 45 0x2D Note The value 0x00 indicates Exciting Field is turned off The value 0x01 indicates Exciting Field is turned on and selecting field mode as voltage mode getting the value of duty cycle through next commend The value 0x03 also indicates Excitin
12. Kelly KDC Series PM Motor Controller User s Manual V 3 3 Kelly KDC Series PM Motor Controller User s Manual KDC72800 KDC72801 KDC72802 KDC72803 KDC12602 KDC12603 Rev 3 3 Dec 2012 Kelly KDC Series PM Motor Controller User s Manual V 3 3 Contents Chapter 1 CIRT 2 TWO MW iia Qu N ta ina 2 Chapter 2 Main Features and Specifications 3 2 1 General tacita a CIT 3 A cpm TT 3 2 S e ecriileiion me au PN EE 4 Chapter 3 Wiring and Installation 5 3 1 Mounting trie Controller uec y L x dt cm rte ae rian 5 So GONNE CONS a LN S eet a a e SE NO tax 7 3 9 INStallallonsGNSCKIIS beads aos 17 Chabter 4 Mallenances estrias 18 lG SOI A amaya Ea 18 AO o u eor eic A rens SE u us 18 dable LED CODES u u u u ua yu aa aaa aras 19 Table 2 1 KDC Controller CAN Commands List 21 Table 2 2 KDC Controller J1939 Instructions 25 ec HP t 27 Kelly KDC Series PM Motor Controller User s Manual V 3 3 Chapter1 Introduction 1 1 Overview This manual introduces the Kelly KDC Series PM 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 Kelly Controls LLC Kelly s programmable motor co
13. User s Manual V 3 3 operation 3 3 aan uuu Wrong connection Valid throttle signal is between 1V 4V Fault report of throttle because signal is less than 0 5V or greater than 4 5V 3 4 ona soon Non zero throttle Controller won t allow a direction change unless the on direction throttle or speed is at zero Fault clears when change throttle is released 4 1 nooo n Regen Motor drive is disabled if an over voltage is detected over voltage during regen The voltage threshold detection level is set during configuration 4 2 anon nn Field error 1 Field did not reach the configured current 2 Field circuit open Please check field wiring 4 3 unun oon Motor Motor temperature has exceeded the configured over temperature maximum The controller will shut down until the motor temperature cools down 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 time between two flashes is 0 5 second The pause time between multiple flash code groups is two seconds Kelly KDC Series PM Motor Controller User s Manual V 3 3 Table 2 1 KDC Controller CAN Commands List Version 1 1 You should specify when sending ID Our default ID is Ox6B so only the data frame with ID 107 can be received by our controller However it can be set by configuration program Frame type data frame Fram
14. e format standard 11 bits ID Length the number of data field bytes Data field data 0 is the command which indicates the operation 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 one or two data frames in response Commands definitions Command CCP_FLASH_READ Length 3 data 0 OxF2 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 controllers model no E g 0x4B 0x44 0x43 is K D C 0x30 is 0 INFO MODULE NAME constant is defined as 64 0x40 Command CCP FLASH READ Length 3 data 0 OxF2 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 0x53 Command CCP FLASH READ Length 3 data 0 OxF2 data 1 CAL TPS HIGH DEAD ZONE data 2 1 Controller response Length 1 data 0 TPS High Dead Zone Desccription Getting controllers Throttle high end dead zone CAL TPS HIGH DEAD ZONE constant is defined as
15. e is defined as temperature of high side FETMOS heat sink and LS TEMP A D value is defined as temperature of low side FETMOS heat sink B A D value of battery voltage BEMF A D is defined as Back EMF Ib A D value of armature driving current Ic A D value of regeneration current Kelly KDC Series PM Motor Controller User s Manual V 3 3 10 If you are using Separately excited motor Va A D value of field voltage at reversing Vc A D value of field voltage at forwarding Otherwise Va and Vc are returned OXFF Command CCP_MONITOR Length 1 data 0 0x33 Controller gives one frame in response Length 8 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 Data 6 voltage of battery data 7 current accounts for percent of the rated current of controller 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 OxFF 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 C Command COM SW ACC Length data 0 data 0 2 0x42 COM READING Cont
16. ea It should have smooth acceleration and good top speed Kelly KDC Series PM Motor Controller User s Manual V 3 3 Chapter4 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 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 it 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 USB port Disconnect motor
17. emperature Operating Temperature Range 30C to 90C 100C shutdown controller case temperature Motor Current Limit 1 minutes 600A 800A depending on the model Motor Current Limit continuous 240A 320A depending on the model Kelly KDC Series PM Motor Controller Model 1 minutes continuous Nominal Voltage Max operating Field Regen current current Range voltage KDC72800 800A 320A 24V 72N 18V 90V KDC72801 800A 320A 24V 72V 18V 90V n KDC72802 800A 320A 24V 72N 18V 90V KDC72803 800A 320A 24V 72V 18V 90V i KDC12602 600A 240A 24V 120V 18V 136V KDC12603 600A 240A 24V 120V 18V 136V Kelly KDC Series PM Motor Controller User s Manual V 3 3 Chapter 3 Wiring and Installation 3 1 Mounting the Controller The controller can be oriented in any position which should be as clean and dry as possible and if necessary shielded with a cover to protect it from water and contaminants To ensure full rated output power the controller should be fastened to a clean flat metal surface with four screws A thermal joint compound can be used to improve heat conduction from the case to the mounting surface The case outline and mounting holes dimensions are shown in Figure 1 Caution RUNAWAYS Some conditions could cause the vehicle to run out of control Disconnect the motor or jack up the vehicle and get the drive wheels off the ground before attempting any work on
18. er at switch on V 3 3 Kelly KDC Series PM Motor Controller User s Manual 3 2 2 Standard Wiring of KDC Series or PM Motor Controller Precharge Resistor 1KQ 10W 0 T F8X LN o gap U jeuondo st 1oystULIET zz panpa aq III sseujqaurq pued juo 3T 2 AIT ETINI UL Jp uuop noi way Ay lt qnezep iq payepndodap st snq NFD g uo Yvatgq 10 101203002 md 133 SUL Ipo Xue 10J q 3114 Apa mMoes ased quur xs 0 mdmo jp rdw pue speururi3 pua oau 0 N TM PUL 4s 24144 qeus 310 01 se pasn aq UE r j urenu od yo g 3pomnp As 0 ALON L C i rere t NI Ot eee we TNYD EENVI XLTETCXE XuctXu FI NIS Copa tl ET Peussey NIN EI TI pauasay peusssu 71 11 Pese TNY II OLASexER H NVO OL 6 Ms easy XLTETSa 6 8 MSODIA XETETSU 8 L mdmo As NIN 4 9 NV awg agzima 9 S spmonr NIH S mm NGEL maudy 7 I amd UMd 1 ct If g Ax xg T lu Jazzng 351242 puendo Az Vus gt CTI gt 5 5 E amp L A 3 lt lem S d 9 2 Z 5 AZ O v E E a A a VSAT AGOIC VE A00T 3GOIG JOJOJA SATIS gt IO SUL qoas Ay Figure 4 KDC series motor controller standard wiring V 3 3 Kelly KDC Series PM Motor Controller User s Manual Precharge Resistor IKQ 10W LT Battery ctor ain Conta M Coil
19. g Field is turned on but selecting field mode as current mode invalidate other values 22 Kelly KDC Series PM Motor Controller User s Manual V 3 3 23 Commend Length 3 CCP_FLASH_READ data 0 OxF2 data 1 0x2C data 2 1 Controller response Length 1 data 0 The value of duty cycle at voltage mode when exciting field is enabled Description Getting the value of duty cycle at voltage mode when exciting field is enabled Command CCP A2D BATCH READ 1 Length 1 data 0 Ox1b Controller gives one frame in response First frame Length 8 data 0 Brake A D data 1 TPS A D data 2 SP A D data 3 TEMP A D data 4 HS TEMP A D data 5 LS TEMP A D data 6 B A D data 7 BEMF A D Command CCP_A2D_BATCH_READ 2 Length 1 data 0 Oxia Controller gives one frame in response Length 4 data 0 IB A D data 1 ICA D data 2 Va A D data 3 VcA D Description Data batch reading 1 LIE mo M For operation voltage B Va BEMF 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 A D value and voltage mapping relation is 120 134 mapping to 4 75 5 25V 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 SP A D value of motor temperature TEMP A D value of controller temperature HS TEMP A D valu
20. ma 200V 3A Diode Key Switch p paussay NIN El O O CI ae PASH TI 11 Pausa TNVO II TNYO JMS INLIZ OLMS YE H NVO 01 HNYO 6 MS asia XLCECSN 6 XLtCXW 8 ASODUN METETSU XTX L mimo Ac 0 T FSA LY 0 yImug p WY jeuondo sr IOJSTULIIJL ax paonpai aq JIM ssy Suq pued uo g qTT IM TT VTIS ue J uu03 NOA UAA lt lt Nepp Aq pajemdodop st snq NY g uo MY3 1 10 10 3EJU03 Md IAIN Suri 121 0 Kuu 310Jaq g 311 J9 IMDIS ISVILA TRUSTS x 0 majo gra ada pue SIEUTUILI3 pua 044 0 N TM DUE AS IMAA TRUSTS a porq su p sn aq ue tr utr epnu od N 0 4ION CAT Pea eT uva ma JOJOJA SOTS Jazzng SA puondO Az Vu GHT I Weald x Figure 5 KDC Series motor controller standard wiring without Reversing Contactor 10 V 3 3 J Battery Precharge Resistor IKO I0W Kelly KDC Series PM Motor Controller User s Manual OCT FSALY 9 y nug p ura euondo st 10jsruriaqg pa2 npai aq pu ss mwu uiq pued yuo GITP 3T eu13x ue PINOY noi USAN aegop lt q paremdodap st sq Ny g uo qea1q 10 1039300 ynd Paay Suum ypo ine a10J2q g Aw ipm ased quusrs As 0 yndyno pw r d pue sqeururra pua 0143 0 NIM PUL AS 231 Ay A amp 0 jndjno 0 pasn aq UE 13j2uenusj0d ILON 1 NIE st parese 11 pause tt Pasa LAS 3519139 PENS OLAS era 6 MS auarwy MES 8 ASODUN L m mo A
21. ntrollers provide efficient smooth and quiet controls for electric vehicles like golf carts go carts electric motorcycles forklifts and hybrid vehicles as well as electric boats and industrial motor speed control It uses high power MOSFET s and fast 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 Kelly KDC Series PM Motor Controller User s Manual V 3 3 Chapter2 Main Features and Specifications 2 1 General functions 1 Extended fault detection and protection The LED flashing pattern indicates the fault sources 2 Monitoring battery voltage It will stop driving if the battery voltage is too high and it will progressively cut back motor drive power as battery voltage drops until it cuts out altogether at the preset Low Battery Voltage setting 3 Built in current loop and over current protection 4 Configurable motor temperature protection range 5 Current cutback at low temperature and high temperature to protect battery and controller The current begins to ramp down at 90 Ccase temperature shutting down at 100C 6 The controller keeps monitoring battery recharging voltage during regenerative braking progressively cutting back current as battery voltage rises then cutting off regen altogether when voltage goes
22. o normal 2 Check battery volts amp recharge if required 1 4 a none Over temperature 1 Controller case temperature is above 90 C warning Current will be limited Reduce controller loading or switch Off until controller cools down 2 Clean or improve heatsink or fan 2 2 nu nu Internal volts fault 1 Measure that B amp PWR are correct when measured to B or RTN 2 There may be excessive load on the 5V supply caused by too low a value of Regen or throttle potentiometers or incorrect wiring 3 Controller is damaged Contact Kelly about a warranty repair 2 3 nn Over temperature The controller temperature has exceeded 100 C The controller will be stopped but will restart when temperature falls below 80 C anna 24 an Throttle error at power up 1 The throttle got effective signal at key on Cycle throttle can remove the error You may reconfigure throttle effective range or foot switch 2 The acceleration throttle must be turned from zero up to high when the brake is released Otherwise the controller will report this fault Frequent reset May be caused by over voltage bad motor intermittent earthing problem bad wiring etc 3 2 nuu of 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 19 V 3 3 Kelly KDC Series PM Motor Controller
23. roller response Length data 0 1 Current throttle switch status Description Getting Throttle switch status 1 active 0 inactive COM READING constant is defined as O Command COM SW BRK Length data 0 data 0 2 0x43 COM_READING Controller response Length data 0 1 Current Brake switch status Description Getting Brake swith status 1 active 0 inactive COM READING constant is defined as O Command COM SW REV Length data 0 data 0 2 0x44 COM_READING Controller response Length data 0 1 Current Reverse switch status Description Getting Reverse swith status 1 active 0 inactive COM READING constant is defined as O 24 Kelly KDC Series PM Motor Controller User s Manual V 3 3 NOTICE 1 CAN bus rate should be configured to 1Mbit s 2 If the command is out of above commands Controller response Length 1 J1939 PDU eee ee data 0 CCP INVALID COMMAND Description CCP INVALID COMMAND constant is defined as Oxe3 Table 2 2 KDC Controller J1939 Instructions PDU Protocol Data Unit contains 29 bits extended format ID and data field ID7 0 is SA ID15 8 is PS ID23 16 is PF ID24 is DP ID25 is R ID28 26 is P Definitions P is Priority R is Reserved DP is Data Page PF is PDU Format PS is PDU Specific SA is Source Address Note The definition of PS depends on the PF If the value of the PF field is below 240 then the PS field is a de
24. s 9 NY awg S sory b mmu NIE T NIE I umd H ct aa Weak sz Fuse Diode 200V 3A TV eae ne iring KDC PM motor controller standard wi Figure 6 11 V 3 3 Kelly KDC Series PM Motor Controller User s Manual Precharge Resistor 1KQ 10W Diode 200V 3A Iepad HUIA AS 0 Jms Ko 3monr AS 0 OST FSA LM 0 JMEJSP urajr jeuondo st JOJSFULISUL se paonpar aq FIM ssaujyqsriq pued juo qTT M T3 EURIA ue IUO NOA WAJAN 2 mepp Aq pajemdodop st snq NFD a g uo Yva iq Io OPRYD Jnd PAN Suri 19130 Xue a10J3q g M XT In3 s asea d Teus 4c 9 ndyno gra 12dra pure speururi3 pua 044 0 NIY PUB AS IMAA TEUSIS IOI se pasn aq ue 13jaurenua 0d MN 0 TION 3030 A PUSEI wung 7 TuondO Az Yus gt CAT Wat lt Figure 7 KDC PM motor controller standard wiring without Reversing Contactor 12 Kelly KDC Series PM Motor Controller User s Manual V 3 3 3 2 3 Front Panel of KDC Sep Ex 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 8 Figure 8 Front panel of KDC Sep Ex Controller B M battery positive and armature positive B battery negative M armature negative S1 Field positive S2 Field negative S1 and S2 Connect to mo
25. stination address DA If the value of the PF field is 240 to 255 then the PS field contains a Group Extension GE value After power up controller will send a message for address claimed to the global address Controller will respond to the PGN requested if the message received by controller is Request PGN message which PF field is 234 If the message received by controller is a command the controller will execute corresponding operation and then send ACK or NACK message to the global address respectively representing executing command or not We have defined our PGNs on the DataPage1 The data fields of every response message has 8 bytes Undefined bytes set as OxFF The Message for Address Claimed R is 0 DP is 0 PF is 238 PS is 255 the global address Data Field is the NAME of CA Controller Application E g P is 3 SA of this node is 0x80 and the NAME of CA is 0x80 00 00 00 00 00 00 30 the Message for Address Claimed is 0x0C OxEE OxFF 0x80 0x30 0x00 0x00 0x00 0x00 0x00 0x00 0x80 The first four bytes is ID and the last eight bytes is the NAME of CA the lowest byte of NAME is sent firstly finally the highest byte of NAME Preferred Address and NAME of CA Controller Application are programmable It can be set by configuration program The default value as follows Preferred Address 63 configurable limit 0 127 248 253 NAME 10 fields Arbitrary Address Capable Fields 1 1 bit 0 disable 1 enable Industry Group Fields 0
26. too high 7 Maximum reverse speed is configurable to half of the maximum forward speed 8 Configurable and programmable with a host computer though RS232 or USB Provide free GUI which can run on Windows XP 2000 Windows 7 and Vista recommend using Kelly Standard USB To RS232 Converter 9 Provision of a 5 volt output to supply various kinds of sensors including Hall effect type 10 3 switch inputs which are activated by connection to Ground Default to throttle switch brake switch and reversing switch 3 analog 0 5V inputs that default to throttle input brake input and motor temperature input Pulsed reverse alarm output Main contactor driver Cutting off the power if any fault is detected Maximum reverse power is configurable to half power Configurable motor over temperature detection and protection with the recommended hermistor KT Y84 130 Optional CAN bus 16 18 120V power supply for 120V controller 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 Intelligence with powerful microprocessor Synchronous rectification ultra low drop and fast PWM to achieve very high efficiency Voltage monitoring on voltage source 12V and 5V Hardware over current protection Hard
27. tor field coil Motor moves forward when current flow from S1 to S2 in the case of REV switch open J1 Pin Definition 1 PWR Controller power supply output 2 Kelly Current meter lt 200mA 3 Main contactor driver lt 400mA Not be used for 120V system 4 Alarm To drive reverse beeper lt 200mA Not be used for 120V system 5 RTN Signal return 6 Green LED Running indication 7 RTN Signal return 8 RS232 receiver 9 RS232 transmitter Figure9 The connecting 10 CAN bus high Optional diagram of J1 and J2 11 CAN bus low Optional 13 Kelly KDC Series PM Motor Controller User s Manual V 3 3 12 Reserved 13 RTN Signal return or power supply ground 14 Red LED Fault code J2 Pin Definition 1 PWR Controller power supply input 2 RTN Signal return or power supply ground 3 RTN Signal return 4 Motor temperature input Demand use KTY84 130 Silicon temperature sensors 5 Throttle analog input 0 5V 6 Brake analog input 0 5V 7 5V 5V supply output lt 40mA 8 Micro_SW Throttle switch input 9 Reverse switch input 10 Brake switch input 11 Reserved 12 Reserved 13 Reserved 14 RTN Signal return 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 Kelly Ammeter positive connect to 5V power supply of
28. ware over voltage protection Current limit and torque control 3 Kelly KDC Series PM Motor Controller User s Manual V 3 3 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 Configuring current voltage mode of field function on controller with field to achieve more reliable Configurable high pedal protection the controller will not work if high throttle is detected at power on Brake switch is used to start regen 0 5V brake signal is used to command regen current Standard PC Laptop computer is used to do programming No special tools needed User program provided Easy to use No cost to customers 2 3 Specifications Frequency of Operation 16 6kHz Standby Battery Current 0 5mA Controller power supply current PWR lt 150mA Configurable battery voltage range B Max operating range 18V to 136V 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 Temperature Range OC to 40C controller case t
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