Kelly Motor Controller
Contents
1. C the warning error current will cut back threshold Release or reduce throttle to ensure the temperature fall 21 Throttle sensor 1 Check whether the connecting is correct fault 2 Check whether the throttle type is correct 3 If configured 0 5V hall throttle check whether the voltage is over 5V 4 Whether connects to the front panel or the back panel conform to configured throttle type 2 2 an Internal voltage 1 Check whether the B and PWR voltage are fault correct 2 Please check load on 5V supply 3 The controller is damaged 2 3 ann Over temperature 1 When controller s temperature is over 100 C it error will stop driving in order to protect itself 2 Stop driving and wait for temperature fall Once temperature falls below 80 the controller will restart driving 2 4 anon Throttle error at 1 The throttle outputs non zero signal at power on power on 2 Step on throttle while turn power on Then the fault is recoverable 3 1 The controller 1 fault will disappear after restarting resets frequently 3 2 Ban on Internal reset Reset caused by over current or so It is normal if occurring occasionally 12 Kelly KDS Small Series PM Motor Controller User s Manual V 1 0 The LED flashes once at power on then keeps on for normal operation 1 2 means it flashed once then flashes twice after 0 5 second The time between two fla2. fifth letters represent the max rating voltage KDS represent Kelly small series PM motor controller Kelly Small DC Motor Controller Model 1 Minute Current Amp Continuous Current Amp Voltage Volt KDS24050E 50 30 12 24 KDS24100 100 40 12 24 KDS24200 200 80 12 24 KDS24100E 100 60 12 24 KDS24200E 200 120 12 24 KDS36050E 50 30 24 36 KDS36100 100 40 24 36 KDS36200 200 80 24 36 KDS36100E 100 60 24 36 KDS36200E 200 120 24 36 KDS48050E 50 30 24 48 KDS48100 100 40 24 48 KDS48200 200 80 24 48 KDS48100E 100 60 24 48 KDS48200E 200 120 24 48 KDS72100 100 40 24 72 KDS72200 200 80 24 72 1 24V model range of the max operating voltage is 8 30V 2 36V model range of the max operating voltage is 18 45V 3 48V model range of the max operating voltage is 18 60V 4 72V model range of the max operating voltage is 18 90V 4 Kelly KDS Small Series PM Motor Controller User s Manual V 1 0 Chapter3 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 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 RUNAWAY
3. Kelly KDS Small Series PM Motor Controller User s Manual V 1 0 Kelly Small Series PM Motor Controller User s Manual Devices Supported KDS24050E KDS24100 KDS24200 KDS24100E KDS24200E KDS36050E KDS36100 KDS36200 KDS36100E KDS36200E KDS48050E KDS48100 KDS48200 KDS48100E KDS48200E KDS72100 KDS72200 Rev 1 0 Feb 2008 Kelly KDS Small Series PM Motor Controller User s Manual V 1 0 Content Chapter 2 2 Chapter 2 Main Features 5 3 2 1 General 3 22 e a e eee EEE 3 2 3 3 4 Chapter Wiring 5 3 1 Mounting the 5 32 OMNIS CONS 6 3 3 Installation CGC OU 10 Chapter ee 11 6 cca A AE 11 Table 5 12 Contact 13 Kelly KDS Small Series PM Motor Controller User s Manual V 1 0 Chapter 1 Introduction 1 1 Overview The manual introduces Kelly motor controllers features installation and maintenance Rea
4. ND pins are internally connected V 1 0 Kelly KDS Small Series PM Motor Controller User s Manual 3 2 3 Standard Wiring of Series and PM Motor Controller ey Switch K Precharge Resistor BATTERY FTILLOWHL g uo aaay sapo Aue 5 4 AS ndhno pasn ag uw TALON Z uonoun AAS 4 15904 AS c 5 5 4 10D 2 IEN NE uonounp Figure 6 Series motor controller standard wiring V 1 0 Kelly KDS Small Series PM Motor Controller User s Manual Fuse 2 a Precharge Resistor g 109 nd sasay TULA sapo Aue punas 956214 pasn aq uw ION z uonounp ASO 4 z uonounp LNANVIA Yad 15141 lt 7 PM motor controller standard wiring Figure Kelly KDS Small Series PM Motor Controller User s Manual V 1 0 3 3 Installation Checkout Before operating the motor complete the following checkout procedures Use LED code as a reference The LED codes are listed in Table 1 Caution Put the vehicle up on blocks to get the drive wheels off the groun
5. S Some conditions could cause the motor 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 short circuit 2 2 11 78 R of tt 122 Tall 44mm Figure 1 mounting holes dimensions dimensions in millimeters 5 Kelly KDS Small Series PM Motor Controller User s Manual V 1 0 3 2 Connections 3 2 1 Front Panel of Serial or PM Motor Controller 3 metal bars are provided for connecting to the battery and motor in the front of the controller shown as Figure 2 Figure 2 Front panel of Serial or PM Motor Controller M output to armature negative B battery positive and armature positive B battery negative Caution Make sure all connections are correct before applying power Otherwise it may damage the controller Please securely wire B before applying power It s preferred to place contactor or breaker on B Please place precharge resistor any breaker can cause damage without it 3 2 2 Back Panel of Serial or PM Mot
6. d 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 small series PM motor controllers provide efficient smooth and quite controls for electrical tricycle electric motorcycle pump motor and industry motor speed control It uses high power MOSFET synchronous rectification fast PWM to achieve high efficiency Kelly KDS Small Series PM Motor Controller User s Manual V 1 0 Chapter 2 Main Features and Specifications 2 1 General functions 1 Extended fault detection and protection LED flashing code indicates fault source Monitoring battery voltage Stop driving if battery voltage is too high or too low Built in current loop and over current protection Controller temperature measurement and protection 5 Cutting back current at low temperature and high temperature to protect battery and controller The current will ramp down quickly if controller s temperature is higher than 90 C and shut down at 100 C Low temperature current ramping down usually starts at 0 C 6 Configurable to limit max reverse speed to half of max forward speed 7 0 5V throttle input 5V sensor supply provided 2 2 Features 5V sensor supply High current metal bar Small size Easy to use Used with PM or series motor Low cost Super high efficiency E model available Intelligence with powerful micro
7. d before beginning these tests Do not allow anyone to stand directly in front of or behind the vehicle during the checkout Make sure both the PWR switch and the brake are off Use well insulated tools sure the wire is connected correctly Turn the PWR switch on LED should blink then keep on when the controller operates normally If this does not happen check continuity of the PWR switch circuit and B connection The fault code will be detected automatically at restarting Close the switch and operate the throttle The motor should spin If it does not operate check the voltage at controller terminals The motor should run faster with increasing throttle If not refer to Table 1 LED code and correct the fault according to the code Kelly KDS Small Series PM Motor Controller User s Manual V 1 0 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 Proper safety precautions should be taken before any work These include but are not limited to proper training wearing eye protection avoiding loose clothing and jewelry and using insulated tools 4 1 Cleaning Although the controller requires actually no maintenance after properly installed the following mi
8. nor maintenance is recommended in certain applications e Remove power by disconnecting the battery e Discharge the capacitors 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 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 Kelly KDS Small Series PM Motor Controller User s Manual Table 1 LED CODES LED Code Explanation Solution Off power or 1 Check whether the connection is correct operating 2 Check fuse and power supply switch On Normal operating That s great You got solution 1 2 on Over voltage error 1 Battery voltage is higher than max operating voltage of the controller Please check the battery voltage 2 The controller will attempt to clear the fault code automatically after 5 second if voltage returns to normal 1 3 Low voltage error 1 controller will attempt to clear the fault code automatically after 5 second if voltage returns to normal 2 Check the battery voltage 3 Charge battery if necessary 1 4 a Temperature 1 When controllers temperature is over 90
9. or Controller Q ____ Kelly SCI Converter 7 N CNTLR Figure 3 Back Panel and Port Figure 4 SCI Converter A SCI port is provided to communicate with RS232 of host computer for calibration and configuration Please note only a special SCI Converter provided by Kelly Controls can be used Please use straight RS232 cable to connect with PC Download and setup the configuration software http www newkellycontroller com support php Kelly KDS Small Series PM Motor Controller User s Manual V 1 0 9 Junction 4 2 111 Green Brown Coil Driver LED 7 6 8 Orange Blue Black 5V Power Throttle GND Junction 2 p 4 5 10 5 5 White Black Micro_ Sw GND Figure 5 Definition of Controller s junction 9 PWR red Controller power supply usually to key switch 1 GND black LED cathode and sensor return 4 Contactor Coil Driver green It s a low side driver Please use PWR as the coil high side 2 LED brown To anode of LED 7 Throttle 5V power source orange 0 5V throttle power input 6 Throttle blue 0 5V throttle input 8 GND black TPS return and switch ground 5 Micro_SW white Close to GND to activate Default as throttle switch Notes All of the above G
10. processor Synchronous rectification ultra low drop and fast PWM to achieve very high efficiency Current measurement control loop and hardware limit Low e Battery protection current cut back shutdown and warning battery Rugged aluminum housing for maximum heat dissipation protection Current cutback at low temperature and high temperature to protect battery and controller High pedal protection Disable operation if power up with non zero throttle 2 3 Specifications Contactor Coil Drive 2 5V Supply Output 30mA Frequency of Operation 16 6 2 Standby Current less than 3mA Throttle Input 0 5 Volts Potential meters can be used to produce 0 5V Meter Alarm output 100mA Power Operating Temperature Range 0 C to 50 C controller case temperature Operating Temperature Range 30 C to 90 C 100C shutdown controller case temperature Peak Current 1 minute 50 200A depending on model Continuous current 30 120A depending on model 2 3 4 Kelly KDS Small Series PM Motor Controller User s Manual V 1 0 2 4 Models The naming regulations of the motor controller model KDS36200E The ninth letter represents some special characteristics represents high efficiency sixth seventh and eighth letters represent the max current The fourth and
11. shes is 0 25 second The pause time between one error code and another error code is 1 second Contact Us Kelly Controls LLC Home Page http www newkellycontroller com E mail support kellycontroller com Phone 01 224 637 5092
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