Kelly KDZ Series / PM / Sep-Ex Motor Controller User`s Manual
Contents
1. pad od aa YA YOM UES FY NEP aq pua pued you Qa Ap 97 wax MOA yy ep Ag payeyndodap snq NY YEA JIE OOS pnd ATK DOULA ADE 9 amp aera TUS Agg dod no p adua pue Spensa OM OF ALDH AS SE pasi aq 5 0 ALLON Battery al H J Contactor Main Diode 200V 13 asna Key Switch INON SI 1 FI NLA Suey OLAS 6 MWS g AAS penny L wding 5 ayaa KN Pa Fi MLH Pay cl I M gt gt TAT Pe x Figure 5 KDZ Series motor controller standard wiring without Reversing Contactor 10 V 3 3 Kelly KDZ Series PM Sep Ex Motor Controller User s Manual Precharge Resistor Fuse Main Contactor TA SEDAT JO IEIUO WIIATY yas aq wes ATI yy MEI sasn apop oy ye asra asad Apuanhbasgns ipagoadsa guid pue gmd oy pur jod wo aud a YA 40K DED FY 1 114 mep Way JOTI lt Panpa aq Ma ssuq pued gT Al EUAN2. yod siog pA SEA od a YA YO WED FY gagy Battery 16 4111 F Li Main Contactor Pole 03 NEP pE T aq ssa ag pued 97 197 O MOA AA HEP Ag payeyndodap s snq j OULU ADE 9 3 46 9 pea Jade pue euma OF POE AS SE aq 11 LON NLH aI Purl 1 NLH 15 pasay gt TNYJ II OLAS 01 H NYJ XYTETSH E 2 0 ACI 1 JOPIEIUO AMY T CTT a 8 L AS L a 01 9 es NG ATA E i T Wael Figure 4 KDZ series motor controller standard wiring V 3 3 Kelly KDZ Series PM Sep Ex Motor Controller User s Manual Precharge Resistor IKEE LOW yras padde aq avanos AT SUI sasn adag ASO guid tr pur gmd
3. 16 Kelly KDZ Series PM Sep Ex Motor Controller User s Manual V 3 3 Chapter 4 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 e 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 it 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 USB port e Disconnect motor wiring from controller e Do not connect B
4. ISI OA A yy Ag papeqndodap si smq WE a YRAUG Nd OL JOO ADE g Aas aeRO INC NG PLA Jad POE spea OF AL PUE AS AS aq WED AsO Tern pausing qg Pa Fl 1 Peery ol TNYT BAY M XPIELSH LLON lt WTitsad NIH 9 NLH ugy Jpg iad Figure 6 KDZ PM motor controller standard wiring 11 V 3 3 atse padde aq sayy Hei FAHA ased ApmanhasqneApaqoadsas sud rai gud cf Jac 44 pur JAU wea Hihii 0 3 SOSA 4 Ponpa aq jawed yoo ap 97 90 A Ag sng Jaep DOU ADE ampa g APIs EY 4g dyno pra PUR pema pia AS se pasni aq UES agape nmap LON 31 Puri cl re Peay cl TNY 2 I i
5. on direction change 4 1 nooo Regen over voltage 4 nooo aan Motor over temperature 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 19 Controller won t allow a direction change unless the throttle or speed is at zero Fault clears when throttle is released Motor drive is disabled if an over voltage is detected during regen The voltage threshold detection level is set during configuration 1 Field did not reach the configured current 2 Field circuit open Please check field wiring Motor temperature has exceeded the configured maximum The controller will shut down until the motor temperature cools down
6. or switch Off until controller cools down Clean or improve heatsink or fan 2 2 mo ana 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 2 3 mo aan Over temperature The controller temperature has exceeded 100 The controller will be stopped but will restart when temperature falls below 80 C 2 4 aa Throttle error at 1 The throttle got effective signal at key on Cycle power up throttle can remove the error You 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 3 1 noo Frequent reset May be caused by over voltage bad motor intermittent earthing problem bad wiring etc 3 2 noo on Internal reset May be caused by some transient fault condition like a temporary over current momentarily high or low IN battery voltage This can happen during normal operation 3 3 noo oon Wrong connection Valid throttle signal is between 1V 4V Fault report of throttle because signal is less than 0 5V or greater than Kelly KDZ Series PM Sep Ex Motor Controller User s Manual V 3 3 3 4 noo aana Non zero throttle
7. s Manual a Teute aq wes asnos AZI SWI EE sasn apop ye a aed Apuanbasgqns4pagoadsas quid zp pur curd zp oy pod 31 aa UES 1 1 yy aq 1 pued qa A aT AIUD MOA HAY yy NEP Ag pawmdodap s snq WW g OIE OOS ADE A ApS dyno pue PUD OF ALP AS se aq WED 5 0 ALON gt Wile gt ex FL NL aT Pa Fl pasy NLH l IAG DATH cl paee TI i PAS TNO 1 6 A HNV M 2 6 fick 5 pemg 2 uaa t pote ao 1 If Ac a 2 Fer 5 0 Coil TJA Precharge Resistor Kad LOW Lh Main Contactor Key Switch Diode 200 Figure 10 KDZ Sep Ex Motor Controller Standard Wiring 15 Kelly K
8. AW M a 2 5 6 a Battery OAc 1 p yas Aay A 3 Precharge Resistor Diode PURER Kelly KDZ Series PM Sep Ex Motor Controller User s Manual IXH NIH 4 E gemd ha gt sy Figure 7 KDZ PM motor controller standard wiring without Reversing Contactor 12 Kelly KDZ Series PM Sep Ex Motor Controller User s Manual V 3 3 3 2 3 Front Panel of KDZ 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 KDZ Sep Ex Controller B M battery positive and armature positive B battery negative M armature negative S1 Field positive S2 Field negative S1 and 82 Connect to motor field coil Motor moves forward when current flow from 51 to S2 the case of REV switch open J1 Pin Definition 1 12V output lt 40mA Optional 2 Kelly Current meter lt 200mA 3 Main contactor driver lt 2mA 4 Alarm drive reverse beeper lt 200 5 Signal return 6 Green LED Running indication 7 RTN Signal return 8 Reserved 9 Reserved Figure9 The connecting 10 Reserved diagram of J1 and J2 11 Reserved 13 Kelly KDZ Series PM Sep Ex Motor Co
9. DZ Series PM Sep Ex Motor Controller User s Manual V 3 3 3 2 5 Communication Port A 5232 port of controller is provided to communicate with host computer for calibration and configuration O looooolO Figure 11 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 e 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 controller ground 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 in a clear area It should have smooth acceleration and good top speed
10. Kelly KDZ Series PM Sep Ex Motor Controller User s Manual V 3 3 Kelly KDZ Series Sep Ex Motor Controller User s Manual KDZ24200 KDZ48303 0472200 KDZ12400 KDZ24201 KDZ48400 KDZ72201 KDZ12401 KDZ24202 0248401 KDZ72202 KDZ12402 KDZ24203 0448402 0472203 KDZ12403 KDZ24300 KDZ48403 02472300 KDZ24301 KDZ48550 KDZ 2301 KDZ24302 KDZ48551 KDZ72302 KDZ24303 0448552 KDZ7 2303 KDZ24400 0448553 KDZ7 2400 KDZ24401 KDZ48650 KDZ 2401 KDZ24402 KD2Z48651 KDZ72402 KDZ24403 0448652 KDZ7 2403 KDZ48653 02472550 KDZ48200 KDZ72551 KDZ48201 KDZ64400 KDZ7 2552 KDZ48202 KDZ64401 KDZ72553 KDZ48203 0464403 KD2Z7 2650 KDZ48300 KDZ72651 KDZ48301 KDZ48302 Rev 3 3 Aug 2013 Kelly KDZ Series PM Sep Ex Motor Controller User s Manual V 3 3 Contents Chapter MTOdUCUON arsos ata 2 E D E EREE 2 Chapter 2 Main Features and 3 ZN General TUN CUON E 3 ZZ Ne AUS S E A E E A EE TEE E 3 2 SO 4 24 NAMING Regulas 9 Chapter Wiring and Installation 5 3 1 MOUNTING the CONTIONED sac sccccssasnasescgcisadess sisters devedevedcerseuspoutiadacasseneadvavacsdandsones 5 AC ONNO CION ese SE 3 2 1 Front Panel of KDZ Series or PM Mot
11. e 3 switch inputs brake switch reversing switch throttle or forward switch Active low 11 analog 0 5V inputs that default to throttle input brake input and motor temperature input 12 Pulsed reverse alarm output 13 Maximum reverse power is configurable to half power 14 Configurable motor over temperature detection and protection with the recommended thermistor KTY84 130 15 Optional 12V output power which can only be applied for Switch signals or LED Any heavy load is inhibited A M 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 eSynchronous rectification ultra low drop and fast PWM to achieve very high efficiency Voltage monitoring on voltage source 12V and SV Hardware over current protection Hardware over voltage protection eCurrent limit and torque control Kelly KDZ Series PM Sep Ex Motor Controller User s Manual V 3 3 EMC 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 e Rugged high current terminals and rugged aviation connectors fo
12. ntinuous 80A 260A depending the model Kelly KDZ Series PM Sep Ex Motor Controller User s Manual V 3 3 2 4 Naming Regulations KDZ48301 The eighth letter represents regeneration 0 Series or PM motor controller 1 PM motor controller with regen 2 Sep Ex or Shunt motor controller 3 Sep Ex or Shunt motor controller with regen The sixth and seventh letters the max current 10 The fourth and fifth letters represent nominal voltage The first three letters represent Kelly s compact DC motor controller 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 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 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 circui
13. ntroller User s Manual V 3 3 12 Reserved 13 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 or 0 5K 6 Brake analog input 0 5V or 0 5K 7 5V 5V supply output lt 40mA 8 Forward switch input 9 Reversing switch input 10 Brake switch input 11 Throttle switch 12 Reserved 13 Reserved 14 RTN Signal return Notes 1 All RTN pins are internally connected 2 Kelly Ammeter positive connect to 5V power supply of controller negative to J1 2 3 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 3 2 4 Standard Wiring of KDZ Sep Ex Motor Controller Kelly KDZ Series PM Sep Ex Motor Controller User
14. or 3 2 2 Standard Wiring of KDZ Series PM Motor Controller 9 3 2 3 Front Panel of KDZ Sep Ex Motor 13 3 2 4 Standard Wiring of KDZ Sep Ex Motor 15 31220 COMMUNICATION a E 16 Sed GMCCKIS 16 Chapter 4 MAING ANGE 17 Cl 17 AZ ON AU ON 17 Table T EED CODE S aert e 18 T 19 Kelly KDZ Series PM Sep Ex Motor Controller User s Manual V 3 3 Chapter 1 Introduction 1 1 Overview This manual introduces the Kelly KDZ Series PM Sep Ex 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 controllers 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 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 paramete
15. r small signal e Thermal protection current cut back warning and shutdown at high temperature Configurable Current Mode or Voltage Mode when Field Switch is enabled to achieve higher safety and reliability Configurable high pedal protection the controller will not work if high throttle is detected at power on switch is used to start regen 0 5V or 0 5K brake signal is used to command regen current Capable of detecting short circuit fault in the main contactor at power e Easy installation 1 4V Hall Active throttle or 0 5K or 0 5V potentiometer lt 100K can work Standard PC Laptop computer is used to do programming No special tools needed eUser program provided Easy to use No cost to customers 2 3 Specifications e Frequency of Operation 16 6KHz Standby Battery Current lt 0 5mA Controller power supply current PWR lt 150 Configurable battery voltage range B Max operating range 8V to 136V e Standard Throttle Input 0O 5K 2 wire resistive pot 0 5V 3 wire resistive pot 1 4V hall active throttle e Analog Brake and Throttle Input 0 5V or 0 5K e Reverse Alarm Main Contactor Coil Driver Meter eFull Power Temperature 0 0 50 controller case temperature Operating Temperature Range 30 to 90 100 shutdown controller case temperature e Motor Current Limit 1 minutes 200 650 depending on the model e Motor Current Limit co
16. rn 4 12V high level brake and motor temperature input Demand use KTY84 130 Silicon temperature sensors 5 Throttle analog input 0 5V or 0 5K 6 Brake analog input 0 5V or 0 5K 7 5V 5V supply output lt 40mA 8 Forward switch input 9 Reversing switch input 10 Brake switch input 11 Throttle switch 12 Reserved 13 Reserved 14 RTN Signal return Notes 1 All RTN pins are internally connected 2 Kelly Ammeter positive connect to 5V power supply of controller negative to J1 2 3 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 V 3 3 Kelly KDZ Series PM Sep Ex Motor Controller User s Manual 3 2 2 Standard Wiring of KDZ Series or PM Motor Controller Precharge Resistor LKQ LOW aate yas padde aq wes AZI puode WE adig apoy ayy og ga puanbasqgng ipagoadsaa guid gy pur gmd m ada
17. rs conduct tests and obtain diagnostic information quickly and easily Kelly KDZ Series PM Sep Ex Motor Controller User s Manual V 3 3 Chapter 2 Main Features and Specifications 2 1General 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 100 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 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 Multifunctional and configurabl
18. t before working on the motor control circuit Wear safety glasses and use properly insulated tools to prevent short circuit Kelly KDZ Series PM Sep Ex Motor Controller User s Manual V 3 3 H i ta oo DJ my 130 145 Height 62 millimeters Figure 1 KDZ mounting holes dimensions dimensions in millimeters Kelly KDZ Series PM Sep Ex Motor Controller User s Manual V 3 3 3 2 Connections 3 2 1 Front Panel of KDZ 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 KDZ motor controller B battery positive and armature positive B battery negative M armature negative J1 Pin Definition 1 12V output lt 40mA Optional 2 Kelly Current meter lt 200mA 3 Main contactor driver lt 2A 4 Alarm To drive reverse beeper lt 200 5 Signal return 6 Green LED Running indication 7 Signal return 8 Reserved Figure 3 The connecting 9 Reserved diagram of J1 and J2 10 Reserved 11 Reserved 12 Reserved 13 Signal return or power supply ground 14 Red LED Fault code Kelly KDZ Series PM Sep Ex Motor Controller User s Manual V 3 3 J2 Pin Definition 1 PWR Controller power supply input 2 RTN Signal return or power supply ground 3 RTN Signal retu
19. throttle and so on The controller may display fault code in some conditions but it doesn t affect programming or configuration e Use a straight through RS232 cable or USB Converter provided by Kelly to connect to a host computer e Provide gt 18V to PWR either J2 pin1 Wire power supply return to any RTN pin Download the free configuration software from http www kellycontroller com support php Caution e 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 17 Kelly KDZ Series PM Sep Ex Motor Controller User s Manual V 3 3 Table 1 LED CODES LED Code Off switched off 2 Check fuse and power supply Green Normal operation That s great You got solution 1 2 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 1 3 Low voltage error The controller will clear after 5 seconds if battery volts returns to normal Check battery volts amp recharge if required Over temperature Controller case temperature is above 90 C warning Current will be limited Reduce controller loading
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