User`s Manual - Kelly Controls
Contents
1. 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 e Remove power by disconnecting the battery starting with battery positive s 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 e 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 e 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 e Disconnect motor wiring from controller e Do not connect B throttle and so on The controller may display fault code in som2. Motor Controller B battery positive and armature positive B battery negative A armature negative S field negative Kelly Controls LLC Figure 4 Back Panel of HSR Motor Controller Kelly HSR Series Motor Controller with Regen User s Manual V 3 3 J he J1 Pin Definition IF ip TC aS E i 2 O 1 Reserved d OQ 2 Kelly Current meter lt 200mA A 12 7 3 Main contactor driver lt 2A S i 13 VU 4 Alarm To drive reverse beeper lt 200mA O 5 RTN Signal return 4 Q ey 6 Green LED Running indication 06 O24 9 7 RTN Signal return i eae 8 Reserved 9 Reserved Figure 5 The Connecting 10 CAN bus high Optional Diagram of J1 and J2 11 CAN bus low Optional 12 High level brake 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 Motor temperature input Demand use KT Y83 122 Silicon temperature sensors 5 Throttle analog input 0 5V 6 Brake analog input 0 5V 7 5V 5V supply output lt 50mA 8 Throttle or forward switch input 9 Reversing switch input 10 Brake switch input 11 Reserved 12 Reserved 13 Reserved 14 RTN Signal return Notes All RTN and GND pins are internally connected but isolated from B Caution Do not apply power until you are certain the controller wiring is correct and has been double checked
3. Regen Motor drive is disabled if an over voltage is detected NIS over voltage during regen The voltage threshold detection level is set during configuration 4 2 aonn ooo Field error 1 Field did not reach the configured current all aiai ida 2 Field circuit open Please check field wiring 4 3 aana son Motor 1 Motor temperature has exceeded the configured over temperature maximum The controller will shut down until the motor temperature cools down 2 Can change the temperature setting in configuration program 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 Contact Us Kelly Controls LLC Home Page http www kellycontroller com E mail support kellycontroller com Phone 01 224 637 5092 14
4. User s Manual V 3 3 3 2 3Communication Port A RS232 port of controller is provided to communicate with host computer for calibration and configuration Ola l O O OOQ Q O Figure 7 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 e 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 e Make sure the wire is connected correctly e 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 return e The fault code will be detected automatically at restart e 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 e Take the vehicle off the blocks and drive it ina clear area It should have smooth acceleration and good top speed 11 Kelly HSR Series Motor Controller with Regen User s Manual V 3 3 Chapter 4
5. 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 s 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 V 3 3 KQ 20W 7 Precharge Resistor Kelly HSR Series Motor Controller with Regen User s Manual 3 2 2 HSR Series Motor Controller Wiring Diagram PIII 51 A9AIAUOD 3000 PREISI ATL a s z ZZ TON A DA 93 Nap Way BUONO sy IOSUA yyy panpa aq JIM ssauysisg jaued 11041 GIT IP AAT JEUX UE 129103 NOA UY AA yy yneyap Aq payeindodap s snq NVD Y 01 NLY PIULO 1 0001 g UO YEI 10 10398 N09 Ind 13AN uM IIO AuB 30190 Q IIM ApIANIAS ISI AS 0 INdjno 01 pasn aq UBD J9 9NITTEHUII0g ALON rl NLU GAT Pea FI gi pawasoy NLY i TI ponosoy VH ATI TI 11 paano TNYJ II OLAS AWE H NV OI s paxisssy MS AMONI pau ssy inding As NLU NV awg aq usg Imo NLY sasu MUSI l r uey smaudwy paiesoy At Vulg gt CAT PPA xxx Battery a P T WE P 99 d a P T WE P aD 0 Zr NM JBI Feud w At Vulg gt U ELl Main Contactor 10 iagram D iring Motor Controller with Regen Wi les HSR Seri Figure 6 Kelly HSR Series Motor Controller with Regen
6. Kelly HSR Series Motor Controller with Regen User s Manual Kelly HSR Opto lsolated Series Motor Controller with Regen User s Manual HSR72601 HSR72801 HSR12401 HSR12601 HSR12901 HSR14301 HSR14501 HSR14701 Rev 3 3 Dec 2011 Kelly HSR Series Motor Controller with Regen User s Manual V 3 3 Contents Chapter 1 Introductionis a a a a 2 TIVOVEVIEW snee TTT 2 Chapter 2 Main Features and Specifications see ee eee ee ee 3 24 General TUMCUOMS e e e a eaaa e S E aa EN EE ae a ea rain 3 22 IT 4 23 OPEC AON e eri r ea eae eeaeee a ae a aoea Nee EA EE Enar Ea a 4 Chapter 3 Wiring and Installation sse eee eee eee e 5 3 1 Mounting the Controle lic sees id eee eee eee eee 5 3 2 GONMECIONS sauna nee aoe ake eae 8 3 2 1 Panels of HSR Series Motor Controller sees 8 3 2 2 HSR Series Motor Controller Wiring Diagrams sese ee 10 3 2 3Communication BOT sees eee eee 11 3 3 AStallatlOn GHECKIIS tess eee eee 11 Chapter 4 Maintenance cccccccececcecsenceeeeneeeceeneeeseneeesseeeessseeeeeseseeseneeeeas 12 Lela Te 12 a COU O Naseer TTT 12 Tabled LED CODE TTT 13 Contact TTT 14 Kelly HSR Series Motor Controller with Regen User s Manual V 3 3 Chapter 1 Introduction 1 1 Overview This manual introduces the features installation and maintenance of the Kelly High Power Opto isolated Series Motor Controller with Regen Read the manual carefully and thoroughly before using the controller If you have any questions please conta
7. ct the support center of Kelly Controls LLC Kelly HSR programmable motor controllers provide efficient smooth and quiet controls for high power electric vehicles like forklifts and hybrid vehicles as well as electric boats and industrial motor speed control It uses high power MOSFETs and high frequency 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 HSR Series Motor Controller with Regen User s Manual V 3 3 Chapter 2 Main Features and Specifications 2 1General functions 1 Extended fault detection and protection Red LED flashing pattern indicates the fault sources and Green LED indicates normal operation Controller will shut down in some fault conditions 2 Built in current loop and over current protection 3 Current cutback at low temperature and high temperature to protect battery and controller The current begins to ramp down at 90 C case temperature shutting down at 100C 4 Configurable motor over temperature detection and protection with the recommended thermistor KTY83 122 5 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 Volta
8. e conditions but it doesn t affect programming or configuration s Use a straight through RS232 cable or USB converter provided by Kelly to connect to a host computer Provide a 8 30V supply to PWR J2 pin1 Wire power supply return to any RTN pin isolated from B 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 12 Kelly HSR Series Motor Controller with Regen User s Manual V 3 3 Table 1 LED CODES LED Code aa No power or 1 Check if all wires are correct Off switched off 2 Check fuse and power supply ae an Normal operation That s great You got solution S S Over voltage error 1 Battery voltage is too high for the controller Check battery volts and configuration Regeneration over voltage Controller will have cut back or stopped regen This only accurate to 2 upon Overvoltage setting Low voltage error The controller will clear after 5 seconds if battery volts returns to normal Check battery volts amp recharge if required anon Over temperature Controller case temperature is above 90 C warning Current will be limited Reduce controller loading or switch Of
9. ery Current depending on the model usually less than 2mA Controller input power PWR less than 10W Controller supply voltage range PWR 8 to 30V Configurable battery voltage range B Max operating range 18V to 180V depending on the model Standard Throttle Input 0 5 Volts 3 wire resistive pot 1 4 Volts hall active throttle Analog Brake and Throttle Input 0 5 Volts 0 5V signal is produced by 3 wire pot e Reverse Alarm Main Contactor Coil Driver Meter Full Power Temperature Range 0 C to 50 C controller case temperature Operating Temperature Range 30 C to 90C 100C shut down controller case temperature e Motor Current Limit 1 minutes 300A 900A depending on the model e Motor Current Limit continuous 135A 405A depending on the model Kelly HSR Series Motor Controller with Regen User s Manual V 3 3 Kelly HSR Series Motor Controller with Regn Model 1 minutes continuous Nominal Voltage Max operating Hegan T current current Range voltage HSR72601 600A 270A 24V 72V 18V 90V HSR72801 800A 360A 24V 72V 18V 90V 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 or six screws A thermal joint comp
10. f until controller cools down Clean or improve heatsink or fan Internal volts fault Measure that B amp PWR are correct when measured to B or RTN There may be excessive load on the 5V supply caused by too low a value of Regen or throttle potentiometers or incorrect wiring Controller is damaged Contact Kelly about a warranty repair Over temperature The controller temperature has exceeded 100 C The controller will be stopped but will restart when temperature falls below 80 C 2 aana Throttle error at The throttle got effective signal at key on Fault power up clears when throttle is released You may reconfigure throttle effective range or foot switch The acceleration throttle must be turned from zero up to high when the brake is released Otherwise the controller will report this fault ee reset May be caused by over voltage bad motor ee 55 earthing problem bad wiring etc 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 P e E of throttle because signal is less than 0 5V or greater than 1 3 1 4 2 2 2 3 L Kelly HSR Series Motor Controller with Regen User s Manual V 3 3 OR 0 3 4 aaa aana Non zero throttle Controller won t allow a direction change unless the ondirection throttle or speed is at zero Fault clears when change throttle is released 4 1 auna n
11. ge setting 6 Monitoring battery recharging voltage during regenerative braking progressively cutting back current as battery voltage rises then cutting off regen altogether when voltage goes too high 7 Multifunctional and configurable 3 switch inputs brake switch reversing switch throttle or forward switch Default to active low customizable active high 8 3 analog 0 5V inputs that default to throttle input brake input and motor temperature input 9 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 10 Maximum reverse speed is configurable to half of the maximum forward speed 11 Maximum reverse current is configurable to half of the maximum forward current 12 Configurable limit for motor current 13 Capable of connecting to Kelly Ampmeter positive to 5V power supply of controller negative to J1 2 14 Provision of a 5 volt output to supply various kinds of sensors including Hall effect type 15 Pulsed reverse alarm output 16 Main contactor driver Cutting off the power if any fault is detected 17 Optional CAN Bus 18 Field driving capability is equivalent to armature 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 Controlle
12. ound 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 and 2 Caution e 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 the motor control circuitry s 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 HSR Series Motor Controller with Regen User s Manual 162 Figure 1 Height 84 millimeters Length 204 millimeters Controller models with above dimension HS R72601 HSR72801 HSR12401 HSR12601 HSR14301 HSR14501 V 3 3 Kelly HSR Series Motor Controller with Regen User s Manual Figure 2 Height 84 millimeters Length 286 millimeters Controller models with above dimension HSR12901 HSR14701 V 3 3 Kelly HSR Series Motor Controller with Regen User s Manual V 3 3 3 2 Connections 3 2 1 Panels of HSR Series Motor Controller Four 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 Figure 5 Figure 3 Front Panel of HSR
13. r may stop regen without warning to protect itself or the battery it won t protect youl Kelly HSR Series Motor Controller with Regen User s Manual V 3 3 2 2 Features Opto isolated technology achieves stability Intelligence with powerful microprocessor Synchronous rectification ultra low drop and fast PWM to achieve very high efficiency Voltage monitoring on voltage source 5V e Hardware over current protection Hardware over voltage protection Current limit and torque control eLow EMC LED fault code Battery protection current cutback warning and shutdown at configurable high and low battery voltage e Rugged aluminum housing for maximum heat dissipation and harsh environment Support fan or water cooling e Rugged high current terminals and rugged aviation connectors for small signal e Thermal protection 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 Provide free User Program Easy to use No cost to customers Current multiplication Take less current from battery output more current to motor Easy installation 1 4V Hall Active throttle or 3 Wire potentiometer lt 100K can work 2 3 Specifications e Frequency of Operation 16 6kHz e Standby Batt
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