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Kelly HPM Controllers User Manual

1. gt iring HPM motor controller standard wi Figure 6 11 Kelly HPM High Power Full Bridge Permanent Magnet Motor Dc Controller User s Manual 3 3 3 2 3 Communication Port RS232 port of controller is provided to communicate with host computer for calibration and configuration O O 9 0 Figure 7 standard RS232 interface 3 3 Installation Checklist Before operating the vehicle complete the following checkout procedures Use LED code as areference 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 on the PWR switch the Red flashes once and the Green is off After the start up delay normally the Red will stay off and the Green will turn on If there is error the Red LED will flashes for fault codes If the S N less 11xxxxxx Turn on the PWR switch the Red flashes once and the Green is on Normally the Red will stay off If there is error the Red LED will flashes for fault codes The fault code will be detected automatically at restart With the brake switch open select a direction and operate the throttle The motor should spin in th
2. 2 4 aaan Throttle error at Throttle signal is higher than the preset dead zone power up at Power On Fault clears when throttle is released 3 1 uuu n Frequent reset May be caused by over voltage bad motor intermittent earthing problem bad wiring etc 14 Kelly HPM High Power Full Bridge Permanent Magnet Motor Dc Controller User s Manual 3 2 ana 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 3 3 ooo nun Hall throttle is When the throttle is repaired a restart will clear the open or fault short circuit 3 4 aaa nooo 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 uuum n Regen or Start up Motor drive is disabled if an over voltage is over voltage detected at start up or during regen The voltage threshold detection level is set during configuration The max threshold is about 1 25 times of controller rated voltage l e you may set threshold lower than 60V for 48V controller 4 3 aana ono 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
3. stays Off 1 2 means the Red flashes once and after a second pause flashes twice The pause time between multiple flash code groups is two seconds 15 V3 3 Kelly HPM High Power Full Bridge Permanent Magnet Motor Dc Controller User s Manual V3 3 Table 2 HPM 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 Frame 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 Ox4B 0x42 0x4C is K B L 0x30 is 0 INFO MODULE NAME constant is defined as 64 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 Descriptio
4. short circuit Kelly HPM High Power Full Bridge Permanent Magnet Motor Dc Controller User s Manual V3 3 1 Figure 1 Height 84 millimeters Length 204 millimeters Controller models with above dimension 72601 HPM72801 HPM12401 HPM12601 HPM14301 HPM14501 Kelly HPM High Power Full Bridge Permanent Magnet Motor Dc Controller User s Manual V3 3 Figure 2 Height 84 millimeters Length 286 millimeters Controller models with above dimension HPM12801 HPM14701 Kelly HPM High Power Full Bridge Permanent Magnet Motor Dc Controller User s Manual V3 3 3 2 Connections 3 2 1 Front and Back Panels of PM Motor Controller Four metal bars and two plugs J1 J2 are provided for connecting to the battery motor and control signals in the front and back panels of the controller shown as Figure 3 and 4 Figure 3 Front panel of HPM motor controller Battery positive B Battery negative M armature positive M armature negative Kelly Controls LLC Figure 4 Back panel of HPM motor controller Kelly HPM High Power Full Bridge Permanent Magnet Motor Dc Controller User s Manual V3 3 Figure 5 The connecting diagram of J1 and J2 11 1 Reserved 10 CAN bus high Optional CAN bus low Optional 12 Reserved 13 GND Signal return or power supply ground 14 Red LED Fault code J2 Pin Definition ONDARRUN 9 10 11 12 13 14 GND Signal return Motor tem
5. BATCH READ1 Length 1 data 0 Ox1b Controller response Length 5 data 0 Brake A D data 1 TPS A D data 2 Operation voltage A D data 3 Vs A D data 4 B A D Description Data batch reading e For operation voltage B A D value and voltage mapping relation is V Vad 1 84 For 120V controller V Vad 1 39 For 144V controller e Vs is defined as the 5V power supply for Hall sensor control panel ect A D value and voltage mapping relation is 120 134 mapping to 4 75 5 25V e 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 Kelly HPM High Power Full Bridge Permanent Magnet Motor Dc Controller User s Manual V3 3 Command CCP_A2D_BATCH_READ2 Length 1 data 0 Oxia Controller response Length 4 data 0 Ib A D data 1 Ic A D data 2 Vb A D data 3 Vc A D Description Data batch reading 1 For Vb Vc A D value and voltage mapping relation is V Vad 1 84 For 120V controller V Vad 1 39 For 144V controller 2 Ib Ic are defined as the two phase current Command CCP MONITOR1 Length 1 data 0 0x33 Controller response Length 6 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 Description Data batch reading 1 PWM is output duty cycle from 0 to 100 2
6. 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 Two RS232 ports Both can be used for configuration 7 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 8 Provision of a 5 volt output to supply various kinds of sensors including Hall effect type 9 4 switch inputs which are activated by connection to Ground Default to throttle switch brake switch reversing switch and Boost Economy switch input 0 3 analog 0 5V inputs that default to throttle input brake input and motor temperature input 1 Pulsed reverse alarm output 2 Main contactor driver Cutting off the power if any fault is detected 3 Current meter to display both drive and regen current Save shunt 14 Configurable boost switch Enables the maximum output power achievable if the switch is turned on 15 Configurable economy switch Limits the maximum current to half if the switch is turned on 16 Maximum reverse power is configurable to half power 17 Enhanced regen brake function A novel ABS technique provides powerful and smooth regen 18 Configurable 12V brake signal input in lieu of motor tempe
7. regen Support three modes of regenerative braking brake switch regen release throttle regen 0 5V analog signal variable regen An RS232 port allows for configuration programming and software upgrades using the free Windows GUI with your PC Standard PC Laptop computer is used to do programming No special tools needed User program provided Easy to use No cost to customers No adjustment 2 3 Specifications Frequency of Operation 16 6kHz Standby Battery Current depending on the model usually less than 2mA 5V Sensor Supply Current 40mA e Controller supply voltage range PWR 8 to 24V preferred Controller input power PWR less than 10W Standard Throttle Input 0 5 Volts 3 wire resistive pot 1 4 Volts hall active throttle Analog Brake and Throttle Input 0 5 Volts Reverse Alarm Main Contactor Coil Driver Meter Full Power Temperature Range 0 C to 50 controller case temperature Operating Temperature Range 30 C to 90 100 C shutdown controller case temperature Motor Current Limit 1 minutes 300A 800A depending on the model Motor Current Limit continuous 135A 400A depending on the model Kelly HPM High Power Full Bridge Permanent Magnet Motor Dc Controller User s Manual V3 3 Battery Current Configurable Kelly Full Bridge Permanent Magnet DC Motor Controller Model 1 minute Continuous Rated Regen Current Cu
8. Kelly HPM High Power Full Bridge Permanent Magnet Motor Dc Controller User s Manual V3 3 Kelly HPM High Power Full Bridge Permanent Magnet DC Motor Controller User s Manual HPM72601 HPM72801 HPM12401 HPM12601 HPM12801 HPM14301 HPM14501 HPM14701 Rev 3 3 Dec 2012 Kelly HPM High Power Full Bridge Permanent Magnet Motor Dc Controller User s Manual V3 3 Contents ChapterT uus eo terea ed eter eden 2 E 2 Chapter2 Main Features and 3 2 1 96 UNCION S ioo 3 2 2 Fed OS cca a una oa Us 4 2 9 9DOCITIGatlOlls setis ite queen hse nema 4 Chapter Wiring and Installation esses 5 3 1 Mounting the Controller 5 E 8 3 9 Installation Checklist eee oae bred aeo ted aoa 12 Chapter 4 13 ZR 13 4 2 CODTIQur dti ON ss cutis onse ut tu arre itae uet 13 Table Te JEED CODES ette utt e e o Gti b Haus 14 Table 2 Controller CAN Commands List 16 19 Kelly HPM High Power Full Bridge Permanent Magnet Motor Dc Controller User s Manual V3 3 Chapter1 Introduction 1 1 Overview This manual introduces the Kelly HPM motor controllers features their installation and their maintenance Read the manual car
9. a 0 Current Brake switch status Description Getting Brake swith status 1 active O inactive COM READING constant is defined as 0 Command COM_SW_REV Length 2 data 0 0x44 data 0 COM_READING Controller response Length 1 data 0 Current Reverse switch status Description Getting Reverse swith status 1 active 0 inactive COM READING constant is defined as O NOTICE 1 CAN bus rate should be configured to 1Mbit s 2 If the command is out of above commands Controller response Length 1 data 0 CCP INVALID COMMAND Description CCP INVALID COMMAND constant is defined as Oxe3 Contact Us Kelly Controls LLC Home Page http www kellycontroller com E mail support kellycontroller com Phone 01 224 637 5092 19
10. data 1 indicates enabling motor rotation or disabling 1 enable O 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 CCP MONITOR2 Length 1 data 0 0x37 Controller response Length 3 data 0 MSB of error status code data 1 LSB of error status code data 2 present current accounts for percent of the rated current of controller Description Data batch reading 1 Controller error status data 0 lt lt 8 data 1 data 0 M 7 6 5 4 3 2 1 0 data O L 0x44 Ox43 0x42 Ox41 0x34 0x33 0 32 0x31 data 1 M 7 6 5 4 3 2 1 0 data 1 L 0x24 0x23 0x22 0x21 0x14 0x13 0x12 0x11 if data 0 lt lt 8 data 1 0x4008 The corresponding error code is Ox43and 0x14 Command COM_SW_ACC Length 2 data 0 0x42 18 Kelly HPM High Power Full Bridge Permanent Magnet Motor Dc Controller User s Manual V3 3 data 0 COM_READING Controller response Length 1 data 0 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 2 data 0 0x43 data 0 COM_READING Controller response Length 1 dat
11. e 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 area It should have smooth acceleration and good top speed 12 Kelly HPM High Power Full Bridge Permanent Magnet Motor Dc Controller User s Manual V3 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 providing that the battery negative is not earthed If battery negative is earthed disconnect that first e Discharge the capacitors in the controller by connecting a load such as a contactor coil resistor or a horn across the controller s B and B termina
12. efully 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 high efficient smooth and quiet controls for electric vehicles like golf carts forklifts and hybrid vehicles as well as electric boats and industrial motor speed control It uses high power MOSFET s and PWM to achieve efficiencies of up to 9996 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 s HPM high power motor controller is full bridge or 4 quadrant controller It provides fast and reliable electronic direction control There is no arc spark or life limit on motor direction changes Kelly HPM High Power Full Bridge Permanent Magnet Motor Dc Controller User s Manual V3 3 Chapter2 Main Features and Specifications 2 1 General functions 1 Extended fault detection and protection The LED flashing pattern indicates the fault sources Green LED indicates normal operation Controller will shut down in some fault conditions 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
13. ls 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 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 port e Disconnect motor wiring from controller e Do not connect B 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 Kelly USB RS232 Converter to connect to a host computer Provide 10V 30V either J2 pin1 or J1 pin1 to PWR 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 13 Kelly HPM High Power Full Bridge Permanent Magnet Motor Dc Controller User s Manual V3 3 Table 1 LED CODES Green LED Code LED Code Explanation Solution Green Off No power or 1 Check if all wi
14. n 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 Command CCP FLASH READ Length 3 data 0 OxF2 data 1 CAL TPS DEAD ZONE LOW data 2 1 Controller response Length 1 data 0 TPS Dead Zone Low 16 Kelly HPM High Power Full Bridge Permanent Magnet Motor Dc Controller User s Manual V3 3 Desccription Getting controllers Throttle low end dead zone CAL TPS DEAD ZONE LOW constant is defined as 4 Command FLASH READ Length 3 data 0 OxF2 data 1 CAL BRAKE DEAD ZONE LOW data 2 1 Controller response Length 1 data 0 Brake Dead Zone Low Desccription Getting controllers Brake low end dead zone CAL BRAKE DEAD ZONE LOW constant is defined as 5 Command FLASH READ Length 3 data 0 OxF2 data 1 CAL TPS DEAD ZONE HIGH data 2 1 Controller response Length 1 data 0 TPS Dead Zone High Desccription Getting controllers Throttle high end dead zone CAL TPS DEAD ZONE HIGH constant is defined as 38 Command CCP FLASH READ Length 3 data 0 OxF2 data 1 CAL BRAKE DEAD ZONE HIGH data 2 1 Controller response Length 1 data 0 Brake Dead Zone High Desccription Getting controllers Brake high end dead zone CAL BRAKE DEAD ZONE HIGH constant is defined as 39 17 Command CCP A2D
15. perature input Throttle analog input 0 5V Brake analog input 0 5V 5V 5V supply output lt 50mA Micro_SW Throttle switch input Reversing switch input Brake switch input Reserved Reserved Reserved GND Signal return J1 Pin Definition PWR Controller power supply output Current meter lt 200mA Main contactor driver lt 2A Alarm To drive reverse beeper lt 200mA GND Signal return Green LED Running indication GND Signal return Reserved PWR Controller power supply input GND Signal return or power supply ground Kelly HPM High Power Full Bridge Permanent Magnet Motor Dc Controller User s Manual V3 3 Notes 1 All RTN and GND pins are internally connected but isolated from B 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 Kelly Ammeter positive connect to 5V power supply of controller negative to J1 2 4 Switch to ground is active Open switch is inactive a 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 b
16. rature sensor 19 Optional joystick throttle A bi symmetrical 0 5V signal for both forwarding and reversing 20 Configurable motor over temperature detection and protection with the recommended thermistor KTY84 130 21 Using battery powered 22 Optional CAN bus 23 Supply voltage 8V 30V Kelly HPM High Power Full Bridge Permanent Magnet Motor Dc Controller User s Manual V3 3 2 2 Features Opto isolated technology achieve stability Intelligence with powerful microprocessor Synchronous rectification ultra low drop and fast PWM to achieve very high efficiency Electronic reversing no reversing contactor needed fast direction change high reliability and efficiency low noise no arc no wearing no life limit easy maintenance Voltage monitoring on voltage source 12V and 5V Current limit and torque control Configurable torque mode and speed mode 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 Support fan or water cooling Rugged high current terminals and rugged aviation connectors for small signal e Thermal protection current cut back warning and shutdown at high temperature Configurable high pedal protection the controller will not work if high throttle is detected at power on Brake switch is used to start
17. reakers 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 10 V3 3 Kelly HPM High Power Full Bridge Permanent Magnet Motor Dc Controller User s Manual sq 13112400 DADA PAIS ATI O T FS ALLM 3 jeuondo 51 ISTLIA Panpa quu sseunqsriq pued 131 20 ATTI uv j22uuo nos uaq Ay nejap iq paremdodap st NFI g 9 202 uo yeaq 101201002 nd utm ypo iue g pms 1ndino 0 pasn aq uqe TAO d 310 N tI NIE CSI PPE Fl ET pauasey NIG l TI pausseu peusss TI Paueseg TNYO amay OT ANS FDNY 0l msesexez 6 5 8 Ms peus 2 L 1 mdmo Ac NIE i tS 1 LL 1 1 artsy 9 t ee NIE c pus Tame t E duum 1 L S Y o Zu lt i A A wi x a FAV As 0 VOT As 0 5 2 O 28 r m iz N e gt e z i gt 9 7 b p N A IOJOTY pua Sery juouvuriaq 3 2 2 Standard Wiring of HPM Motor Controller NI Soe rr TT cd SENTO yo vns aT PY Jazzng 5
18. res are correct switched off 2 Check fuse and power supply Green On Normal operation Thats great You got solution Green amp Red are both 1 Software still upgrading On 2 Supply voltage too low or battery too high The controller is damaged Contact Kelly about a warranty repair Red LED Code 1 2 un 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 The controller will clear after 5 seconds if battery volts returns to normal 2 Check battery volts amp recharge if required 1 4 uuum Over temperature 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 mo unu Internal voltage Measure that B amp PWR are correct when fault 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 Hu Over temperature The controller temperature has exceeded 100 C The controller will be stopped but will restart when temperature falls below 80 C 1 3 unu Low voltage error
19. rrent Voltage 72601 600A 300A 72V Yes HPM72801 800A 400A 72V Yes HPM12401 400A 200A 120V Yes HPM12601 600A 300A 120V Yes HPM12801 800A 400A 120V Yes HPM14301 300A 135A 144V Yes HPM14501 500A 225A 144V Yes HPM14701 700A 315A 144V Yes Female plugs of J1 amp J2 will be shipped for free 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 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 Applying silicon grease or some other thermal conductive material to contact surface will enhance thermal performance Proper heat sinking and airflow are vital to achieve the full power capability of the controller The case outline and mounting holes dimensions are shown in Figure 1 and 2 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 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

Kelly HPM Controllers User Manual

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