Kelly KDHA High Voltage Series/PM Motor Controller User`s Manual
Contents
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3. Brake switch is used to start regen 0 5V brake signal is used to command regen current 2 3 Specifications Frequency of Operation 16 6kHz Standby Battery Current 3 mA Supply Voltage PWR 8 to 30V Supply Current 200mA 12V or 2 5W Operating Voltage 18V to 136V Analog Brake and Throttle Input 0 5 Volts Can use 3 wire pot to produce 0 5V signal Reverse Alarm Main Contactor Coil Driver Meter 1 5A Full Power Temperature Range OC to 40C controller case temperature Operating Temperature Range 30C to 90C 100C shutdown controller case temperature Motor Current Limit 10 seconds boost 200A 400A 500A 600A 800A depending on model Motor Current Limit 1 minutes 300A 350A 400A 600A 800A depending on model Motor Current Limit continuous 100A 160A 200A 240A 320A depending on model V 3 1 Kelly High Voltage DC Motor Controller Model 10 1 minutes continuous Nominal Max operating Regen seconds current current Voltage voltage boost Range current KDH07600A 600A 600A 240A 24 72 18V 90V KDH07601A 600A 600A 240A 24V 72M 18V 90V 7800 800 800 320 24 72 18V 90V KDH07801A 800A 800A 320A 24V 72M 18V 90V KDH09400A 400A 300A 160A 24V 96V 18V 120V KDH09401A 400A 300A 160A 24V 96V 18V 120V 9500 500 400 200 24 96 18V 120V 9501 500 400 200 24V 96V 18V 120
4. Please contact Kelly if it happens repeatedly 3 2 moo nn Internal reset Reset caused by over current high battery voltage or low supply voltage It is normal if occurs occasionally 3 4 uum noon Throttle isn t zero The controller won t change drive direction if when try to throttle isn t zero Also it won t change direction at change direction high speed The controller will wait throttle and speed close to zero before change direction 4 1 anan n Over voltage at The controller won t drive motor if detect startup or overvoltage at power up It will cut back regen regeneration current or stop regen if detect overvoltage during regen You may set overvoltage threshold with GUI The max threshold is about 1 25 times of controller rated voltage l e you may set threshold lower than 60V for 48V controller 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 Page 16 Kelly KDHA High Voltage Series PM Motor Controller User s Manual V 3 1 Contact Us Kelly Controls LLC Home Page http www kellycontroller com support kellycontroller com Phone 01 224 637 5092 Page 17
5. 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 KDHA High Voltage Series PM Motor Controller User s Manual V 3 1 nj fe lt R4 4 C FET ez 130 14 Tall 62 millimeters Figure 1 mounting hole dimensions dimensions in millimeters Page 6 Kelly KDHA High Voltage Series PM Motor Controller User s Manual V 3 1 3 2 Connections 3 2 1 Front Panel of KDH Motor Controller Five metal bars and two plugs J1 J2 are provided for connections to the battery motor and control signals in the front of the controller shown as Figure 2 Figure 2 Front panel of KDHA motor controller picture Battery positive B Battery negative M Armature Output Figure 3 The connecting diagram of J1 and J2 10 2 NN Xf Pin Definition C 13 C 1 PWR Controller power supply output The pin is Red 8 1 LED for S N less 08XXXXXX Q O 2 Current meter lt 200 NT 5 3 contactor driver lt 1 5 dE ys SR 05 D 4 Alarm To drive reverse beeper lt 200mA 5 GND Signal return 6 Green LED Running indication 7 GND Signal return 8 RS232 receiver 9 RS232 transmitter 10 CAN bus high Optional Page 7 Kelly KDHA High Voltage Series PM Motor Controller User s Manual V 3 1 11 CAN bus low Optional 12 Reserved
6. pad 24818 AS 0 QoS Y P esnd vc L3N9VIN ININVINYAd K ND TNVO XLcCCCX XU CETXA vwe PA GAT 03345 zy thout Reversing Contactor iring wi KDHA PM motor controller standard w Figure 7 Page 12 Kelly KDHA High Voltage Series PM Motor Controller User s Manual V 3 1 3 2 3 Communication Port A RS232 port of controller is provided to communicate with host computer for calibration and configuration O oO Figure 8 standard RS232 interface 3 3 Installation Checklist Before operating the vehicle complete the following checkout procedure 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 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 the PWR switch on The LED should blink then keeps on when the controller operates normally If this does not happen check continuity of the PWR and controller ground 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 the selected direction Plea
7. 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 4 2 Configuration You can configure the controller with a host computer through RS232 e Use a standard RS232 cable connecting the 9pin connector on face penal to a host computer The cable should be straight e Provide 8V to 30V supply to PWR either J2 pin1 or J1 pin14 Wire power supply ground to any GND pin e Do not connect B throttle and so on The controller may display fault code but it doesn t affect programming or configuration Page 14 Kelly KDHA High Voltage Series PM Motor Controller User s Manual Table 1 LED CODES V 3 1 LED Code Explanation Solution Green power or not 1 Check if all wires are correct Off operating 2 Check fuse and power supply Green L 3 Normal operation That s great You got solution On 1 2 n un Over voltage error 1 Battery voltage is higher than max operating voltage of the controller Please check the battery voltage and configuration 2 Over voltage at regeneration Controller will cut back or stop regeneration 1 3 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 Over temperature 1 The controll
8. 13 GND Signal return or power supply ground 14 Red LED Fault code The pin is PWR for S N less 08XXXXXX J2 Pin Definition 1 PWR Controller power supply input 2 GND Signal return or power supply ground 3 GND Signal return 4 Motor temperature input 5 Throttle analog input 0 5V 6 Brake analog input 0 5V 7 5V 5V supply output 40mA 8 Throttle switch input 9 Reverse switch input 10 Brake switch input 11 Reserved 12 Reserved 13 Reserved 14 GND Signal return Notes All GND pins are internally connected Two PWR pins J1 14 and J2 1 are internally connected It s recommended to use J1 14 to supply peripherals like alarm and meters Twist peripheral wires with PWR is the preferred for EMC Recirculation diodes are provided in the controller to PWR for alarm and meter drivers 3 Switch to ground is active Open switch is inactive N a 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 Don t connect GND to B Please place precharge resistor on any breaker It can cause damage without it 3 2 2 Standard Wiring of KDHA Motor Controller Page 8 V 3 1 Kelly KDHA High Voltage Series PM Motor Controller User s Manual Precharge Resistor 3000 10W Battery Fuse Main Contactor 14 sp 43 12400 JA J
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10. Kelly KDHA High Voltage Series PM Motor Controller User s Manual Kelly KDHA High Voltage Series PM Motor Controller User s Manual Rev 3 1 Dec 2008 KDH07600A KDH07601A KDH07800A KDH07801A KDH09400A KDH09401A KDH09500A KDH09501A KDH12400A KDH12401A KDH12500A KDH12501A KDH14200A KDH14201A KDH14400A KDH14401A Kelly KDHA High Voltage Series PM Motor Controller User s Manual V 3 1 Contents Chapter Unies epe Y 2 NES 7 2 Chapter 2 Main Features and 3 NECI PEE 3 2 2 PO AU SS e 3 2 3 Bs 81 81 672 1116 4 Chapter Wiring and 5 3 1 Mo nting the 5 3 2 aycu EEEE EEE 7 3 3 1 5 1 CHECK GUN em 13 Chapter 4 cl 14 hoi E 14 4 2 CONMIGO 14 Table 12 LED CGODES m 15 Contact 17 1 Kelly KDHA High Voltage Series PM Motor Controller User s Manual V 3 1 Chapter1 Introduction 1 1 Overview The manual introduces Kelly HIGH VOLTAGE motor controller features installation and maintenance Read the manual carefully and thoroughly before use the controller Should you have any questions please contact the support center of Kelly Controls LLC Kelly s pro
11. V 12400 400 300 160 24V 120V 18V 136V KDH12401A 400A 300A 160A 24V 120V 18V 136V i KDH12500A 500A 400A 200A 24V 120V 18V 136V KDH12501A 500A 400A 200A 24V 120V 18V 136V KDH14200A 200A 150A 100A 24V 144V 18V 168V KDH14201A 200A 150A 100A 24V 144V 18V 180V KDH14400A 400A 350A 160A 24V 144V 18V 168V KDH14401A 400A 350A 160A 24V 144V 18V 180V T For supply voltage all KDHA controllers are 8V 30V Page 4 Kelly KDHA High Voltage Series PM Motor Controller User s Manual V 3 1 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 Applying silicon gel or other thermal conductive material to contact surface will enhance thermal performance Sufficient heat sink and air flow is required for high power application 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 work on the motor control circuitry HIGH CURRENT ARCS Electric vehicle batteries can supply very high power and arcs can occur if they
12. er temperature is over 90 C The warning controller will cut back current in the case Stop or reduce output to ensure the temperature fall 2 Improve heat sink or airflow 2 1 oo n Throttle sensor 1 Check if the connecting is correct fault 2 Check if the voltage is in 0 5V 2 2 nu Internal voltage 1 Check if the B and PWR voltage are correct fault refer to B or RTN Could be PWR voltage low 2 Please check load on 5V supply Could be high load on 5V Incorrect pot wiring can load it heavily 1 The controller is damaged Please contact Kelly for warrantee 2 3 Hu nnn Over temperature 1 The controller temperature is over 100 Controller stops driving in order to protect itself 2 Stop driving and wait for temperature fall The controller will restart if temperature drops below 80 2 4 aa sono Throttle error at 1 The throttle signal is higher than configured power up dead zone at power on 2 The fault will disappear if restart or release throttle 3 1 non n Frequent reset 1 The controller will stop driving after detect too many resets 2 Mostly because of B or return wiring Use Page 15 Kelly KDHA High Voltage Series PM Motor Controller User s Manual V 3 1 heavier and clean return wires For dual controllers bond B of both controllers together with heavy cable or copper strip 3 Could be over current protection May set max current lower 4 Restart will clear the error 5
13. grammable motor controllers provide efficient smooth and quite controls for electrical vehicles like golf cart go cart electric motorcycle fork lift hybrid vehicle as well as electric boat and industry motor speed control It uses high power MOSFET fast PWM to achieve efficiency 9996 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 KDHA High Voltage Series PM Motor Controller User s Manual V 3 1 Chapter 2 Main Features and Specifications 2 1 General functions 1 Extended fault detection and protection LED flashing for fault code 2 Monitoring battery voltage It will stop driving if battery voltage is too high It will cut back then stop driving if voltage is going too low 3 Built in current loop and over current protection 4 Controller temperature measurement and protection 5 Current cutback at low temperature and high temperature to protect battery and controller The current will ramp down quickly if controller temperature is higher than 90C and shutdown at 100C Low temperature current ramping down usually starts at OC 6 The controller keeps monitoring voltage during regen It will cut back current then cut off regen if voltage is going too high 7 Configurable to limit max reverse speed to half of max forward speed 8 Configurable and p
14. rogrammable with RS 232 Software upgradeable Windows GUI provided 9 Provide 5V sensor supply 10 3 switch inputs Close to ground to activate Default to throttle switch brake switch and reverse switch 11 3 analog inputs 0 5V Default to throttle input brake input and motor temperature input Reverse alarm output Recirculation diodes provided Main contactor driver Cut off the power if any fault detected Configurable max reverse power to half Motor over temperature detection and protection with recommended thermistor Optional CAN bus Optional supply voltage 8V 30V Caution Regeneration has braking effect but cant replace mechanical brake Mechanical brake s required to stop your vehicle Regen isnt a safety feature Controller may stop regen to protect itself not you 2 2 Features Intelligence with powerful microprocessor Synchronos rectification ultra low drop fast PWM to achieve very high efficiency Current limit and torque control LED fault code helps user debugging Battery protection current cut back shutdown and warning at low battery Thermal enhanced rugged aluminum housing Rugged connectors Thermal protection Current cut back on low temperature and high temperature to protect battery and controller High pedal protection Disable operation if power up with non zero throttle Page 3 Kelly KDHA High Voltage Series PM Motor Controller User s Manual
15. se verify wiring and voltage if it doesn t 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 13 Kelly KDHA High Voltage Series PM Motor Controller User s Manual V 3 1 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 virtually no maintenance after properly installation the following minor maintenance is recommended in certain applications Remove power by disconnecting the battery Discharge the capacitors in the controller by connecting a load such as a contactor coil or a horn across the controller s and B terminals 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 Make sure the connections to
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