Kelly Motor Controller
Contents
1. KEY SWITCH TILLOYHL OAS 0 HOLIMS JAS Ya Ade AUVMUOA VI A001 1 1 K D TANVd LNOUW YO ee VASUHAAN YOLOW 1 INANVWNAd Figure 5 PM motor controller standard wiring Page 10 V 2 5 Kelly KD Series DC Motor Controller User s Manual PRECHARGE RESISTOR 3009 1 0W MAIN CONTACTOR BATTERY Fuse y POLE COIL IBe OA DIODE 100V 1A 0 ND ouuoo g Nd IAIN SULIT Aue Q ITM ATAINIS po uojaad SI JA JA AFT AVOL SY PIS WEJ TMS Ayddng AS SV P SN od UBD EMS 0 999044 L AS 0 10 SdL 03 9301 ASISA 5 0 YLA HALON TV dAd AMVA AS 0 Ld Ox TVNOI Ld O 2A Fuse IVNOIIdO 77 ASAJAAYN KEY SWITCH ATLLOYHL OAS 0 HOLIMS 5 VI A001 AGOIG VI A001 TANVd LNOW 7 YOLIVINOD YOLOW LANOVIN 72V PM motor controller alternative wiring Figure 6 Page 11 Kelly KD Series DC Motor Controller User s Manual V 2 5 3 2 3 Front Panel of Sep Ex and Shunt Motor Controller Nine metal bars are provided for connections to the battery control signals motor armature and field in the front of the controller M output to motor armature B battery2. PWR provides power for the controller It is preferred that PWR provides power to switches coils and other accessories It must be capable of carrying the current 2 Reverse switch input Make sure the throttle is released before change direction or controller will stop output It is considered as reverse when the input reaches 0 7 PWR voltage 3 Resistive throttle analog input 0 5K or 5 0K resistive throttle analog input Default to 0 5K Default effective zone is 20 80 Below 1K corresponds to zero speed and above 4K corresponds to full speed If open controller will take AN2 0 5V input as alternative Page 7 V 2 5 Kelly KD Series DC Motor Controller User s Manual 3 2 2 Standard Wiring of Series Wound and PM Motor Controller PRECHARGE RESISTOR 3000 10W MAIN CONTACTOR BATTERY 4 Fuse wr T POLE COIL DIODE 100V 1A osny V7 0 99UU09 3 UO WO 0 yNd BULIM 19q 0 Q ITM ATAINIIS KEY SWITCH HOLIMS AS YJA TA AVMO YOLIVINOD T AVOL SY PIN 9 UBD TMS Ajddng 19M0g AS SY WLI CMS TNV 0 L AS 0 10 SdL 03 91030141 PAYSISAY 5 0 PLA ALON TVNOILd O HOLIMS TVNOILdO TILLOYHL AS 0 TVNOIIdOx WAZ ZN ASAUAATa ATLLOYHL O1S 0 THNVd LNOW Figure 3 Series wound motor controller standard wir
3. blinking code indicates fault sources Battery protection current cut back and turn off should battery voltage low Thermal protection current cut back at high temperature and low temperature to protect battery and controller e Critical parameters can be configured with GUI to best fit your application 2 3 Optional Features Terminals available on back side Following features are configurable through series communication with a host PC RLY can be configured as a Peak and Hold Main Contactor coil driver PWM is an output to drive Reverse Alarm e SW1 as Brake Switch is required for regeneration 0 5V AN1 as Brake analog input can be configured for continuous variable regeneration 0 5V AN2 can be configured as alternative throttle input Page 3 Kelly KD Series DC Motor Controller User s Manual V2 5 e SW2 can be configured as throttle switch SW3 can be used as 5V supply of sensors 2 4 Specifications Frequency of Operation 16 6 KHz e Standby Current less than 3 mA e Controller power supply current PWR 150 e Controller power supply voltage PWR 18V to 90V e Minimum operating voltage B 18V e Max regeneration voltage B 1 25 Nominal Throttle Input 0 5 5 0 K ohms 0 5 Volts Full Power Operating Temperature Range OC to 50 controller case temperature e Operating Temperature Range 30C to 90 C 100C shutdown controller case temperature e Peak and H
4. e Remove any dirt or corrosion from the bus bar area The controller should be wiped with a moist rag Be sure it is dry before reconnecting the battery e sure the connections to the bus bars are tight Use two wrenches for this task in order to avoid stressing the bus bars the wrenches should be well insulated Page 17 Kelly KD Series DC Motor Controller User s Manual V2 5 Table 1 LED CODES LED Code Explanation Solution Off E power or no 1 Check whether the connection is correct operating 2 Check fuse and power supply switch operate normally 1 2 Over voltage error 1 Battery voltage is higher than max operating voltage of the controller Please check the battery voltage 2 Over voltage at regeneration Controller will cut back or stop regeneration 1 3 2 oon Low voltage error 1 The controller will attempt to clear the fault code automatically after 5 second if battery return to normal 2 Check the battery voltage 3 Charge battery if necessary 1 4 a noon Temperature 1 controller temperature is over 90 C The warning error controller will cut back current in the case Stop or reduce output to ensure the temperature fall 2 1 ana Throttle sensor fault 1 Check whether the connecting is correct 2 Check whether the throttle type is correct 3 If configured 0 5V hall throttle check if the voltage over 5V 4 Whether co
5. Chapter 4 1 17 Ad 17 Table 1 LED 18 Contact 20 1 Kelly KD Series DC Motor Controller User s Manual V2 5 Chapter 1 Introduction 1 1 Overview The manual introduces Kelly motor controller features installation and maintenance Read the manual carefully and thoroughly before use If you have any questions please contact the support center of Kelly Controls Kelly s programmable motor controllers provide efficient smooth and quite controls for electrical vehicles like golf cart electric motorcycle fork lift as well as electric boat and industry motor speed control It uses high power MOSFET fast PWM to achieve efficiency gt 99 in most cases Powerful microprocessor brings in comprehensive and precise control to the controllers It also allows users to set parameters conduct tests and obtain diagnostic information quickly and easily Page 2 Kelly KD Series DC Motor Controller User s Manual V2 5 Chapter 2 Main Features and Specifications 2 1 General functions 1 The controller measures battery voltage It won t drive motor if B is higher than the maximum operating voltage It also stops driving if battery voltage is too low You can identify the error from LED code Under voltage threshold and over voltage threshold are configurable with PC GUI 2 The controller will close t
6. Kelly KD Series DC Motor Controller User s Manual User s Manual Devices Supported KD36200 KD36201 KD36202 KD36203 KD36300 KD36301 KD36302 KD36303 KD36400 KD36401 KD36402 KD36403 KD48200 KD48201 KD48202 KD48203 KD48300 KD48301 KD48302 KD48303 KD48400 KD48401 KD48402 KD48403 KD48500 KD48501 KD48502 KD48503 KD48600 KD48601 KD48602 KD48603 KD72200 KD72201 KD72202 KD72203 KD72300 KD72301 KD72302 KD72303 KD72400 KD72401 KD72402 KD72403 KD72500 KD72501 KD72502 KD72503 KD72600 KD72601 KD72602 KD72603 V 2 5 Kelly KD Brushed Motor Controller Rev 2 5 Feb 2008 Kelly KD Series DC Motor Controller User s Manual V2 5 Contents Chapter 1 Introduction 2 le 1 VOC IEW eeo a RR 2 Chapter 2 Main Features and 1 1 1 5 3 2al Genera sessin ee kre 3 Vee oA Osa a a data ete E e E a 3 2 3 Optional Features Terminals available on back side 3 2 4 Specification eat 66 4 2 0 Mod Darrers 4 Chapter 3 Wiring and 1 11 1 5 3 1 Mounting the 5 niches G a E 7 Cheehof wake ARR ae 16
7. S SV PIS 9 UBD TMS Ajddng aoxod AS SV Pasy UBD EMS TNV 9 IWO L AS 0 10 SdL 0IL PAY SISOY MS O PNA ALON TY dAd AJAVAA AS 0 TWNOILdO aNd TVNOILdO K IVNOLIdO WAZ ZN ASA AAT ATLLOYHL OAS 0 HOLIMS 5 ca ld lt A J IV MOLON xa dog Figure 8 Sep Ex Motor Controller Standard Wiring Page 13 V 2 5 Kelly KD Series DC Motor Controller User s Manual PRECHARGE RESISTOR 3009 1 0W MAIN CONTACTOR 4 0 NX 3290009 U0G UO ind 13AIN ULM 19430 AUK 9 IM M S IVA SI JA JA APT YIUAS 9 OAL SY PIN UBD TMS Addng AS SV 9 WEJ EMS TNV 9 IMO L AS 0 10 SdL 0 NOIL ANSISAY MS 0 VNA ALON TY dAd AS 0 IWNOLIdO TVNOILdO Hy gt Vulg gt aT APT IBAON 6 2 A K T TVNOILdO UAZ ZNA ASUAATU 2 Nn THNVd MOVE gt 4 aa ATLLOUHL 8 0 S IANVd LNOW HOLIMS ISATA TY 4 Q AE POLE DIODE 100V 1A ca Id IV YOLOW Figure 9 72V Sep Ex Motor Controller Alternative Wiring Page 14 Kelly KD Series DC Motor Controller User s Manual V2 5 3 2 5 Back Panel Nine metal bars and a communication port are provided on the back panel of each controller shown as Figure 10 O PWM RLY LED GND AN1 AN2 SW1 SW2 SW3 F
8. d automatically at restart e With the brake switch open select a direction and operate the throttle The motor should spin in the selected direction If it does not verify the wiring to the REV switches REV contactors Main contactor and motor Also check fuse The motor should run faster with increasing throttle If not refer to Table 1 LED code and correct the fault according to the code e Take the vehicle off the blocks and drive it in a clear area It should have smooth acceleration and good top speed Page 16 Kelly KD Series DC Motor Controller User s Manual V2 5 Chapter 4 Maintenance There are no user serviceable parts inside the controllers Do not attempt to open the controller Or you will damage it However clearing the controller exterior periodically should be necessary The controller is inherently a high power device When working with any battery powered vehicle proper safety precautions should be taken These include but are not limited to proper training wearing eye protection avoiding loose clothing and jewelry and using insulated wrenches 4 1 Cleaning Although the controller requires actually no maintenance after properly installed the following minor maintenance is recommended in certain applications e Remove power by disconnecting the battery 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
9. he main contactor after power on self test Then it waits a configurable time default to 0 5s for contactor bumping 3 Current loop and over current protection are built in for both field and armature The field current is constant across all operation conditions except in the case of field weakening Armature current is commanded by throttle position sensor 4 The armature current is trimmed down at low temperature and high temperature to protect battery and controller The armature current will ramp down quickly over 90C Both armature and field will shutdown at 100C Low temperature current ramping down usually starts at OC 5 Current cut back at low battery is built in every controller to extend battery life Caution Excessive voltage drop on wiring may cause problem Proper gauge of wire is required 6 The max regeneration current is about half of max output current Caution Regeneration can have braking effect but it cant replace mechanical brake The controller may shut down regen in some Cases 7 Max reverse speed is configurable to half of max forward speed 2 2 Features Intelligence with powerful microprocessor e Synchronous rectification fast PWM and very low drop to provide high efficient Thermal enhanced rugged aluminum housing Current loop and over current protection for both field coil and armature Current multiplication Usually the armature current is much higher than the current draw from battery
10. igure 10 Back Panel of all Controllers PWM can drive one of following reverse alarm RLY main contactor coil driver LED to anode of LED GND LED cathode and sensor return AN1 0 5V brake analog input AN2 0 5V throttle analog input as alternative of 0 5K TPS input SW1 brake switch input active when apply PWR voltage SW2 throttle switch input active when apply PWR voltage 5 3 5V 30mA output as sensor supply Page 15 Kelly KD Series DC Motor Controller User s Manual V2 5 3 2 6 Communication Port A SCI port is provided to communicate with RS232 of host computer for calibration and configuration Please note only a special RS232 Converter by Kelly Controls can be used Please use straight RS232 cable to connect with PC 3 3 Installation Checkout Before operating the vehicle complete the following checkout procedure Use LED code as a reference The LED codes are listed in Table 1 Caution e Put the vehicle up on blocks to get the drive wheels off the ground before beginning these tests e Do not allow anyone to stand directly in front of or behind the vehicle during the checkout e 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 LED should blink then keeps on when the controller operates normally If this does not happen check PWR voltage and controller ground e The fault code will be detecte
11. ing Page 8 V 2 5 Kelly KD Series DC Motor Controller User s Manual PRECHARGE RESISTOR 3000 1 0W MAIN CONTACTOR g 0 IND ouuoo U0G g WO 0 ind BULIM 19470 AU Q IVA d SI 19198009 JA JA SY PIN 9G UBD TMS Aiddng AS SV p SN ux EMS TNV 0 IWO L AS 0 10 SdL 03 VOIL AYSI YS 9 PNA ALON IVNOIIJO HOLMS MVNA TYNOIIdO IBJ 0A BATTERY L E lt N x IVNOLLdO O WAZ ZN ASA JATA Z N gt 8 aa x ATLLOUHL 68 0 HOLIMS AS 1 001 1 01 L gt YOLOW SATS POLE TANVd LNOW DIODE 100V 1A YOLIVINOD 5 72Vseries wound motor controller alternative wiring Figure 4 Page 9 V 2 5 Kelly KD Series DC Motor Controller User s Manual PRECHARGE RESISTOR 3009 1 0W MAIN CONTACTOR BATTERY H Fuse 1 DIODE 100V 1A 0 ND 00UU0d U0G g UO JN SULIT 19430 AUB Q IATA J M S IVd YOMMS AYOL SY PIN 9 UBD TMS AS SV p SN UBD CMS 0 IMO L AS 0 10 SdL OF IHO AYSI MS HYNA HALON TV ddd AVA AS 0 IVNOIIJO IVNOIIJO TVNOILd O 27 9 5
12. irection 4 1 Over voltage error Beyond the setting value of over voltage when when regeneration regeneration or startup can set the value of over voltage by configurable the controller will shop regeneration The voltage reduce to recovery voltage and release brake throttle regeneration get right 4 2 nann on Field error 1 Field do not reach setting current can change by configurable software 2 Field open circuit please check field connecting The LED flashes once at power on then keeps on for normal operation 1 2 means it flashed once then flashes twice after 1 second The time between two flashes is 0 5 second The pause time between one error code and another error code is 2 second Contact Us Kelly Controls LLC Home Page http www kellycontroller com E mail support kellycontroller com Phone 001 224 637 5092 Page 19
13. k 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 circuit before working on the motor control circuit Wear safety glasses and use properly insulated tools to prevent short Page 5 Kelly KD Series DC Motor Controller User s Manual V2 5 Tall 62 millimeters Figure 1 mounting hole dimensions dimensions in millimeters Page 6 Kelly KD Series DC Motor Controller User s Manual V2 5 3 2 Connections 3 2 1 Front Panel of Series Wound or PM Motor Controller Seven metal bars are provided for connections to the battery motor and control signals in the front of the controller shown as Figure 2 M output to motor B battery positive B battery negative PWR controller power supply usually to key switch REV reverse switch input TPS resistive throttle analog input GND TPS return and other signal ground Figure 2 Front panel of Series Wound or PM Motor Controller Caution Make sure all connections are correct before apply power Otherwise it may damage the controller Please securely wire B before applying power It s preferred to place contactor or breaker on B Don t connect GND to B Please place precharge resistor on any breaker It can cause damage without it 1 Power switch The vehicle should have a master switch to turn the controller on and off
14. nnects to the front panel or the back panel according to configured throttle type 2 2 an no Internal voltage fault 1 Check whether the B and PWR voltage are correct 2 Please check load on 5V supply 3 The controller is damaged 2 3 aa mono Over temperature error 1 The controller temperature is over 100 C Controller stop driving in order to protect itself 2 Stop driving and wait for temperature fall Once temperature falls below 80 C the controller will restart driving 2 4 ana aaan Throttle error when startup 1 The throttle have signal at power on It is default to 20 80 is effective eg 0 5K throttle think 1K is 1 4K is 100 can reset throttle Available In or set throttle safety switch by configurable 2 Step on throttle at the same time when power on the fault will disappear restart or release throttle 3 1 The controllers reset times too much 1 Default will disappear after restart Page 18 Kelly KD Series DC Motor Controller User s Manual V2 5 3 2 Ban on Internal reset Reset caused by over current or so It is normal if occurring occasionally 3 3 ann oon Brake sensor error 1 Check whether the connecting is correct 2 Chenk whether the connecting of throttle type is correct 3 4 Throttle have The controller will stop output It will get right after signal when release throttle change d
15. old Main Contactor Driver peak 1A hold e Alarm Output 200mA e Armature Current Limit 1 minutes 200A 300A 400A 500A 600A e Armature Current Limit continuous 80A 120A 160A 200A 240A 2 5 Model The naming regulation of the Kelly motor controller model KD48301 The seventh letter represents the type of controller and whether the controller has regeneration 0 represents Series or PM Motor Controller 1 represents PM Motor Controller with regeneration 2 represents Shunt Motor Controller 3 represents Shunt Motor Controller with regeneration The fifth and sixth letters represent the max current divided by 10 The third and fourth letters represent the max rating voltage The first and second letters represent Kelly s DC motor controller Page 4 Kelly KD Series DC Motor Controller User s Manual V2 5 Chapter 3 Wiring and Installation 3 1 Mounting the Controller The controller can be oriented in any position as clean and dry as possible or shield 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 The case outline and mounting hole 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 wor
16. positive B battery negative F1 field positive F2 field negative PWR power switch input REV reverse switch input TPS resistive throttle analog input GND sensor return Figure 7 Front Panel of Shunt Motor Controller 1 Power switch The vehicle should have a master switch to turn the controller on and off PWR provides power for the controller It is preferred that PWR provides power to switches coils and other accessories It must be capable of carrying the current 2 Reverse switch input Make sure the throttle is released before change direction or controller will stop output It is considered as reverse when the input reaches 0 7 PWR voltage 3 Resistive throttle analog input 0 5K or 5 0K resistive throttle analog input Default to 0 5K Default effective zone is 20 80 Below 1K corresponds to zero speed and above 4K corresponds to full speed If open controller will take AN2 0 5V input as alternative 4 F1 F2 Connect to motor field coil Motor moves forward when current flow from F1 to F2 in the case of REV switch open Page 12 V 2 5 Kelly KD Series DC Motor Controller User s Manual 3 2 4 Standard Wiring of Sep Ex and Shunt Motor Controller PRECHARGE RESISTOR 3000 1 0W MAIN CONTACTOR BATTERY Fuse COIL DIODE 100V 1A KEY SWITCH 0 NX ouuoo U0G g UO 10 9e U09 Nd SULA 194 0 AU Q ITIM J noos ISLA YOUA
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