Kelly Motor Controller
Contents
1. 22 Optional CAN bus 23 Optional supply voltage 8V 30V Page 3 Kelly Full Bridge Permanent Magnet Motor Dc Controller User s Manual V 3 3 2 2 Features e Intelligence with powerful microprocessor Synchronous rectification ultra low drop and fast PWM to achieve very high efficiency e Electronic reversing e Voltage monitoring on voltage source 12V and 5V Current limit and torque control Configurable torque mode and speed mode Low 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 Rugged high current terminals and rugged aviation connectors for small signal Thermal protection current cut back warning and shutdown on high temperature Configurable high pedal protection Disable operation if power up with high throttle Brake switch is used to start regen Support three modes of regenerative braking brake switch regen release throttle regen 0 5V analog signal variable regen Full Programmable with RS 232 Software upgradeable Free Windows GUI software Standard PC Laptop computer 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 0 5mA 5V Sensor Supply Current 40mA C2. 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 Page 15 Kelly Full Bridge Permanent Magnet Motor Dc Controller User s Manual V 3 3 Home Page http Awww kellycontroller com E mail support kellycontroller com Phone 01 224 637 5092 Page 16
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4. area It should have smooth acceleration and good top speed Page 12 Kelly Full Bridge Permanent Magnet Motor Dc 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 or will void warranty However cleaning 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 tools 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 starting with battery positive 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 terminals 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 Make 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 4 2 Configuration You can configure the controller with a host computer throu
5. 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 scooters forklifts and hybrid vehicles as well as electric boat and industrial motor speed control It uses high power MOSFET s and PWM to achieve efficiencies of up to 97 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 PM 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 Page 2 Kelly Full Bridge Permanent Magnet Motor Dc Controller User s Manual V 3 3 Chapter2 Main Features and Specifications 2 1 General functions 1 Extended fault detection and protection LED flashing code indicates fault sources 2 Monitoring battery voltage Stop driving if battery voltage is too high or too low 3 Built in current loop and over current protection 4 Motor temperature input and protection Configurable range 5 Cutting back current at low temperature and high temperature to protect battery and controller The
6. Kelly Full Bridge Permanent Magnet Motor Dc Controller User s Manual V 3 3 Kelly Full Bridge Permanent Magnet Dc Motor Controller User s Manual PM24101 PM24201 PM24301 PM36101 PM36201 PM48101 PM48201 PM48301 PM48401B PM48501B PM72101 PM72201 PM72301 PM72401B PM72501B PM12101H PM12201H Rev 3 3 Mar 2011 Kelly Full Bridge Permanent Magnet Motor Dc Controller User s Manual V 3 3 Contents Chapter TO CIT ON Loo ca este iS nu oM da LE Set Sut b ce a Cu Abi eae 2 EST c Som 2 Chapter 2 Main Features and Specifications 3 2 General TUACHONG u uu anka EUM 3 2 2 TONGS Sia Tt 4 2 SDOGIfISatlOrlS uuu a L sunum IS 4 Chapter 3 Wiring and Installation et etes 6 3 1 Mounting the Controller sss 6 3 2 CONNECCION Ge dieu cec MN Eds ALD A 8 3 3 Installation CheeklSbs Dio t ee tod RE ORDRE UOS 12 Chapter 4 Maintenance EE Uer 13 LEES 13 Configuratio Mt u u eae atas sao uic 13 Table d EED OODES deditus teat em UU m D IE He dca us 14 aT a 2 le ses n M EL ME 15 Page 1 Kelly Full Bridge Permanent Magnet Motor Dc Controller User s Manual V 3 3 Chapter1 Introduction 1 1 Overview This manual introduces the Kelly PM motor controllers features their installation and
7. The fault will disappear if restarts or releases throttle 3 1 noo n Frequent reset 1 It can be caused by over current bad motor bad ground wiring or so 3 2 ano nn Internal reset Reset caused by over current high battery voltage or low supply voltage It is normal if occurs occasionally 3 3 num nun Throttle short or 1 Check whether the throttle is short or open up open circuit when 2 When the throttle is normal restart will clear the using 1 4v hall error sensor throttle 3 4 suum soon 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 changing direction 4 1 nonn mn Over voltage at The controller won t drive motor if detects startup or overvoltage at power up It will cut back regen regeneration current or stop regen if detects 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 4 3 unun Motor over 1 The motor temperature is higher than configured temperature max temperature Controller will shut down and wait for motor temperature dropping 2 Can change the temperature setting with configuration program The Red LED flashes once at power on then keeps off for normal operation
8. V Yes PM12201H 200A 80A 120V 24V 120V Yes Female plugs of J1 amp J2 will be shipped for free Page 5 Kelly Full Bridge Permanent Magnet Motor Dc Controller User s Manual V 3 3 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 holes 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 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 Page 6 Kelly Full Bridge Permanent Magnet Motor Dc Controller User s Manual 26 7 T Height 62 millimeters Figure 1 mounti
9. current will ramp down quickly if controller temperature is higher than 90C and shut down at 100 C Low temperature current ramping down usually starts at 0 6 Two RS232 ports Both can be used for configuration 7 Configurable and programmable with RS 232 Software upgradeable Windows GUI provided 8 Provide power supply 5V for hall sensors and other sensors 9 3 switch inputs Default to throttle switch brake switch and reversing switch Closing to ground is to activate 10 3 analog inputs 0 5V Default to throttle input brake input and motor temperature input 11 PWMable reverse alarm output 12 Main contactor driver Cutting off the power if any fault is detected 13 Current meter to display both drive and regen current Save shunt 14 Configurable boost switch Output can arrive at the maximum current if the switch is enabled and turned on 15 Configurable turbo switch Limit max power to half if the switch is enabled and turned on 16 Configurable max reverse power to half 17 Enhanced regen brake function Novel ABS technique provides powerful and smooth regen 18 Configurable 12V brake signal input in lieu of motor temperature sensor 19 Optional joystick throttle Single 0 5V signal for both forwarding and reversing 20 Thermal overload detection and protection to safeguard the motor from over temperature with recommended Silicon temperature sensors KTY83 122 21 Using battery powered
10. gh RS232 or USB port Use straight through RS232 cable or Kelly Standard USB To RS232 Converter to connect the D9 connector to a host computer Provide gt 18V either J2 pin1 or J1 pint to PWR Wire power supply return to any RTN pin 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 Download and setup the configuration software http www kellycontroller com support php Caution Prohibit connecting controller s configuration software when the motor is running Configuration software will be regularly updated and published on the website Please regularly uninstall the previous configuration software from your computer download and install the new one Page 13 Kelly Full Bridge Permanent Magnet Motor Dc Controller User s Manual Table 1 Green LED Code V 3 3 LED CODES LED Code Explanation Solution Green Off No power or not 1 Check if all wires are correct operating 2 Check fuse and power supply Green On Normal operation That s great You got solution Green and Red LED Keep On 1 Software is upgrading 2 Supply voltage too low or battery too high 3 The controller is damaged Please contact Kelly for warrantee Red LED Code 1 2 Over voltage error 1 Battery voltage is higher than max operating voltage of the controller Please check the batter
11. n or power supply ground 3 RTN Signal return 4 12V high level brake and motor temperature input 5 Throttle analog input 0 5V 6 Brake analog input 0 5V 7 5V supply output lt 40mA 8 Micro SW Throttle switch input 9 Reversing switch input 10 Brake switch input 11 Reserved 12 Reserved 13 Reserved 14 RTN Signal return Notes 1 All RTN pins are internally connected 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 Recirculation diodes are provided in the controller to PWR for alarm and Contactor coil driver 3 Kelly Ampmeter positive connect to 5V power supply of controller negative to J1 2 4 Switch to ground is active Open switch is inactive 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 on any breaker It can cause damage without it Page 9 V3 3 Kelly Full Bridge Permanent Magnet Motor Dc Controller User s Manual 3 2 2 Standard Wiring of PM Motor Controller Battery Cail dil a oc Precharge Resistor Coil 200V 3 ey Switch Diode K paoonpai aq pM soup pued ET FT 7 EUX ug 3330002 noA MAYA
12. ng holes dimensions dimensions in millimeters BL5 114 5 114 21 5 272 304 Height 62 millimeters Figure 2 PM B mounting holes dimensions dimensions in millimeters Jo Os 130 146 V3 3 Kelly Full Bridge Permanent Magnet Motor Dc Controller User s Manual V 3 3 3 2 Connections 3 2 1 Front Panel 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 of the controller shown as Figure 3 Figure 3 Front panel of PM motor controller B Battery positive B Battery negative M armature positive M armature negative Figure 4 The connecting diagram of J1 and J2 J1 Pin Definition gv E 1 PWR Controller power supply output The pin is 14 12 Red LED for S N less 08XXXXXX O 13 e 2 Current meter lt 200mA 8 O 3 Main contactor driver lt 2A N Q 4 Alarm To drive reverse beeper lt 200 gt O O 5 RTN Signal return NR d 6 Green LED Running indication 7 RTN Signal return 8 RS232 receiver 9 RS232 transmitter 10 CAN bus high 11 CAN bus low 12 Reserved 13 RTN Signal return or power supply return 14 Red LED Fault code The pin is PWR for S N less 08XXXXXX Page 8 Kelly Full Bridge Permanent Magnet Motor Dc Controller User s Manual V 3 3 J2 Pin Definition 1 PWR Controller power supply input 2 RTN Signal retur
13. ontroller supply voltage range PWR 18V to B 8V to 30V for Controllers rated equal 24V e Supply Current PWR 150mA 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 to 50C controller case temperature Operating Temperature Range 30C to 90C 100C shutdown controller case temperature Motor Current Limit 1 minutes 100A 500A depending on the model Motor Current Limit continuous 40A 200A depending on the model Max Battery Current Configurable Page 4 Kelly Full Bridge Permanent Magnet Motor Dc Controller User s Manual V 3 3 Kelly Full Bridge Permanent Magnet DC Motor Controller 1 minute Continuous Voltage Model C rr nt Rated Voltage a Regen PM24101 100A 40A 24V 12V 24V Yes PM24201 200A 80A 24V 12V 24V Yes PM24301 300A 120A 24V 12V 24V Yes PM36101 100A 40A 36V 24V 36V Yes PM36201 200A 80A 36V 24V 36V Yes PM48101 100A 40A 48V 24V 48V Yes PM48201 200A 80A 48V 24V 48V Yes PM48301 300A 120A 48V 24V 48V Yes PM48401B 400A 160A 48V 24V 48V Yes PM48501B 500A 200A 48V 24V 48V Yes PM72101 100A 40A 72V 24V 72V Yes PM72201 200A 80A 72V 24V 72V Yes PM72301 300A 120A 72V 24V 72V Yes PM72401B 400A 160A 72V 24V 72V Yes PM72501B 500A 200A 72V 24V 72V Yes PM12101H 100A 40A 120V 24V 120
14. or controller standard wiring Page 11 Kelly Full Bridge Permanent Magnet Motor Dc Controller User s Manual V 3 3 3 2 3 Communication Port A RS232 port of controller is provided to communicate with host computer for calibration and configuration naa O O O 9 O O Figure 7 standard RS232 interface 3 3 Installation Checklist Before operating the vehicle 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 ground before beginning these tests Do not allow anyone to stand directly in front of or behind the vehicle during the checkout e Make sure both the PWR switch and the brake are off Use well insulated tools Make sure the wire is connected correctly Turn the PWR switch on The LED should blink then keep 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 restarting With the brake switch open select a direction and operate the throttle The motor should spin in the selected direction Please verify wiring and voltage if it doesn t operate 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 Take the vehicle off the blocks and drive it in a clear
15. y voltage and configuration 2 Over voltage at regeneration Controller will cut back or stop regeneration 3 Please note there could be 2 error with Overvoltage setting 1 3 nuu Low voltage error The controller will attempt to clear the fault code automatically after 5 second if battery voltage returns to normal 2 Check the battery voltage 3 Charge battery if necessary 14 a aaan Over temperature warning The controller temperature is over 90 C The controller will cut back current in the case Stop or reduce output to ensure the temperature fall 2 Improve heat sink or airflow 2 2 nun nun Internal voltage fault Check if the B and PWR voltage are correct 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 uu nuu Over temperature When controller s temperature is over 100 it will stop driving in order to protect itself 2 Stop driving and wait for temperature fall The controller will restart if temperature drops below 80 C Page 14 V 3 3 Kelly Full Bridge Permanent Magnet Motor Dc Controller User s Manual 2 4 aa aana Throttle error at 1 The throttle signal is higher than configured power up dead zone at power on 2
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