Kelly Motor Controller
Contents
1. 13 14 E 15 Kelly KD Series DC Motor Controller User s Manual V 3 2 Chapter 1 Introduction 1 1 Overview This manual introduces the Kelly motor controllers features their installation and 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 Kelly s programmable motor controllers provide efficient smooth and quiet controls for electric vehicles like golf carts electric motorcycles and forklifts as well as electric boats and industrial motor speed control It uses high power MOSFET s and fast PWM to achieve efficiencies of up to 99 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 KD Series DC Motor Controller User s Manual V 3 2 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 Youcan identify the error from LED codes Under voltage threshold and over voltage threshold are configurable with PC GUI 2 The controller will close the main contactor after power on self test Then it waits a configura2. 0 8541 Haq 10 md PAN Bum Aue g P MII FLAL NV 41 0 MOIL AS 0 40 SAL 03 APOL APSHA 5 0 PPA ALON ms Ieg rwydo w 0 IINE ISIA y 5215 0 Pole Diode 200V YOIMS AUA JOJON SOLES 10 0 0 IS BAY Z Figure 3 Series wound motor controller standard wiring 3 2 Kelly KD Series DC Motor Controller User s Manual Precharge Resistor 1KQ 10W Battery Fuse Main Contactor ISNA VT Pole Coil Diode 200V 3A Key Switch YIM ITMI SSTA oT PEMO VE A00Z VE A007 PONA lt gt oq 8119 pwed M AAT JUU Ua AA 51558 07 g 0 1 5 31 UO yaq JO Aue PN ILAA NV 2841 09 FOIL AS 0 JO SAL 09 ATPOML HARSHA MS 0 LMA ALON AS 0 IINE ISIA y OAS 0 purd JOLT ISDA 1001 PUSE Figure 4 PM motor controller standard wiring Kelly KD
3. Check if the throttle type is correct Check if the voltage is above 5V when use 0 5V hall throttle Check configured throttle type TPS2 should be configured as voltage input if used 2 2 Internal volts fault 1 Measure that B amp PWR are correct PR Over temperature The controller temperature has exceeded 100 C The controller will be stopped but will restart when temperature falls below 80 C 2 4 nana Throttle error at The throttle got effective signal at key on Fault power up clears when throttle is released You may reconfigure throttle effective range or foot switch The acceleration throttle must be turned from zero up to high when the brake is released Otherwise the controller will report this fault May be caused by over voltage bad motor intermittent earthing problem bad wiring etc 3 2 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 4 aana Non zero throttle Controller won t allow direction change unless the on direction throttle or speed is at zero Fault clears when throttle 14 Kelly KD Series Motor Controller User s Manual V 3 2 __ change 4 1 The voltage is higher than the configured overvoltage over voltage value The controller can resume operation when voltage lowered
4. Series DC Motor Controller User s Manual V 3 2 3 2 3 Front Panel of Sep Ex and Shunt Motor Controller Nine metal bars are provided for connecting to the battery control signals motor armature and field in the front of the controller M output to armature negative B battery positive and armature positive B battery negative F1 field positive F2 field negative PWR power switch input REV reversing switch input TPS resistive throttle analog input Kel ly Controller GND sensor return B B Fl Figure 5 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 Reversing switch input Make sure the throttle is released before changing 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 and F2 Connect to motor field coil Motor moves forward when current flow from F1 to F2 inthe case of REV switch open 3 2 Kelly KD Se
5. and brake cycled 4 2 nana on Field error 1 Field did not reach the configured current 2 Field circuit open Please check field wiring The LED flashes once at power on as a confidence check and then stays on for normal operation 1 2 means the Red flashes once and after a second pause flashes twice The time between two flashes is 0 5 second The pause time between multiple flash code groups is two seconds Contact Us Kelly Controls LLC Home Page http www kellycontroller com E mail support kellycontroller com Phone 001 224 637 5092 15
6. to the mounting surface 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 26 wig fg i 216 Height 62 millimeters Figure 1 Dimensions in millimeters Kelly KD Series Motor Controller User s Manual V 3 2 3 2 Connections 3 2 1 Front Panel of Series Wound or PM Motor Controller Seven metal bars are provided for connecting to the battery motor and control signals in the front of the controller shown as Figure 2 M output to armature negative B battery positive and armature positive B battery negative PWR controller power supply usually to key switch REV reversing switch input PWR voltage to activate TPS 0 5K throttle input GND Throttle return Figure 2 Front panel of Series Wound or PM Motor Controller Caution Do not apply power until you are certain the controller wiring is correct and has been double checked W
7. 24V controller Max regeneration voltage B 1 25 Nominal Throttle Input 0 5 5 0 ohms 0 5 Volts e Full Power Operating Temperature Range 0C to 50 controller case temperature e Operating Temperature Range 30C to 90 C 100C shutdown controller case temperature Peak and Hold Main Contactor Driver peak 1A hold Alarm Output 200 Armature Current Limit 1 minute 200A 500A depending on the model Armature Current Limit continuous 80A 200A depending on the model 2 5 Models The naming regulations of the Kelly motor controller model KD48101 The seventh letter represents regeneration 0 Series or PM motor controller 1 PM motor controller with regen 2 Shunt motor controller 3 Shunt motor controller with regen The fifth and sixth letters the max current 10 The third and fourth letters represent nominal voltage The first two letters represent Kelly s compact DC motor controller Kelly KD Series DC Motor Controller User s Manual V 3 2 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 and if necessary shielded witha 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
8. Kelly Compact DC Motor Controller User s Manual User s Manual Devices Supported KD24200 KD24201 KD24202 KD24203 KD24300 KD24301 KD24302 KD24303 KD24400 KD24401 KD24402 KD24403 KD48200 KD48201 KD48202 KD48203 KD48300 KD48301 KD48302 KD48303 KD48400 KD48401 KD48402 KD48403 KD48500 KD48501 KD48502 KD48503 KD72200 KD72201 KD72202 KD72203 KD72300 KD72301 KD72302 KD72303 KD72400 KD72401 KD72402 KD72403 KD72500 KD72501 KD72502 KD72503 V 3 2 Kelly KD Brushed Motor Controller Rev 3 2 Aug 2011 Kelly KD Series DC Motor Controller User s Manual V 3 2 Contents Chapters 2 TA OVE VIEW 2 Chapter 2 Main Features 5 3 27 IGS ie hal functions 3 2 2 og 0 oto ae oe OPER ECE ener nn rane nny Senn 3 2 3 Additional Features Terminals available on back 3 2 4 5 E 4 By E ET 4 Chapter Wiring 5 3 1 Mounting the 5 3 2 CONNECtONS 6 883nstalation GHECKOUL 12 Chapter 4 Maintenance 13 A SIG AMIN
9. ake sure the PWR switch and the brake is off Use well insulated tools e Make sure the wire is connected correctly Turn the PWR switch The LED should blink then stay on steadily when the controller operates normally If this does not happen check PWR voltage and controller ground e 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 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 as determined by the fault code e Take the vehicle off the blocks and drive it ina clear area It should have smooth acceleration and good top speed 12 Kelly KD Series DC Motor Controller User s Manual V 3 2 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 These 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
10. ble time configurable 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 4 The armature current is trimmed down at low temperature and high temperature to protect battery and controller The armature current begins to ramp down at 90C Both armature and field will shut down at 100 5 Current cutback at low battery is built in every controller to extend battery life Caution Excessive voltage drop on wring may cause problem Proper gauge of wre required 6 The max regeneration current is about half of rated current Caution Regeneration can have braking effect but it can t replace mechanical brake The controller may shut down regen in some cases 7 Maximum reverse speed is configurable to half of the maximum forward speed 2 2 Features Intelligence with powerful microprocessor Synchronous rectification fast PWM and ultra low drop to provide high efficiency Rugged aluminum housing for maximum heat dissipation and harsh environment Current loop and over current protection for both field coil and armature Current multiplication Usually the armature current is much higher than the current drawn from battery LED blinking code indicates fault sources protection current cutba
11. ck and turnoff when battery voltage is too low Thermal protection current cuts back at high temperature and low temperature to protect battery and controller eSupport torque mode operation Configuring current voltage mode of field function on controller with field to achieve more reliable Critical parameters can be configured with GUI to best fit your application User program provided Easy to use No cost to customers 2 3 Additional 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 can be configured to drive reverse alarm or current meter Can drive Kelly 3 Kelly KD Series Motor Controller User s Manual V 3 2 Ampmeter directly e BRK SW as Brake Switch is required for regeneration e BRK AN as Brake analog input can be configured for continuous variable regeneration TPS2 AN can be configured as alternative throttle input 3 wire pot or 0 5 sensor can work with the input Please configure as 0 5V throttle should the pin be used Optional Waterproof 2 4 Specifications e Frequency of Operation 16 6 KHz Standby Battery Current lt 0 5mA Controller power supply current PWR lt 150mA Controller supply voltage range PWR 18V to 90V 8V to 30V for 24V controller Minimum operating voltage B 18V 8V for
12. controller requires actually no maintenance after properly installed the following minor maintenance is recommended in certain applications Remove power by disconnecting the battery starting with battery positive e Discharge the capacitors in the controller by connecting a load Such as a contactor coil 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 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 13 Kelly KD Series Motor Controller User s Manual V 3 2 Table 1 LED CODES _ Check if all wires are correct switched off and power supply switch Battery voltage is too high for the controller Check battery volts and configuration Regeneration over voltage Controller will have cut back or stopped regen This only accurate to 2 upon Overvoltage setting The controller will clear after 5 seconds if battery volts returns to normal Check battery volts amp recharge if required Over temperature Controller case temperature is above 90 C warning Current will be limited Reduce controller loading or switch Off until controller cools down Clean or improve heatsink or fan Throttle sensor Check if all wires are correct fault
13. iring 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 breakers 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 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 The wire and fuse must be capable of carrying the current 2 Reversing switch input Make sure the throttle is released before changing direction or controller will stop output Itis considered as reverse if the input gt 0 7 PWR 3 Resistive throttle analog input 0 5K or 5 0K resistive throttle 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 TPS2 AN 0 5V input as alternative 3 2 Kelly KD Series DC Motor Controller User s Manual 3 2 2 Standard Wiring of Series Wound and PM Motor Controller Precharge Resistor 1KQ 10W Battery Pack Fuse Main Contactor asny Key Switch aq PM ssomgysiiq pwed yq M URIX JHU UMM 51556203
14. n TPS2 AN 0 5V throttle analog input as alternative of 0 5 TPS input 5V OUT 5V 30mA output as supply to throttle or brake sensors BRK SW brake switch input active when apply PWR voltage BRK AN 0 5V brake analog input TPS2 SW throttle switch input active when apply PWR voltage SP SW reserved switch input active when apply PWR voltage 3 2 6 Communication Port SCI port is provided to communicate with RS232 of host computer for calibration and configuration Please note only a special RS232 Converter provided by Kelly Controls can be used Please use straight RS232 cable to connect with PC Download the free configuration software from http www kellycontroller com support php 11 Kelly KD Series Motor Controller User s Manual V 3 2 Caution e Make certain that the motor is disconnected before trying to run the configuration software Configuration software will be regularly updated and published the website Please update your Configuration Software regularly You must uninstall the older version before updating 3 3 Installation Checkout Before operating the vehicle complete the following checkout procedures Use LED code as a reference 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 M
15. ries DC Motor Controller User s Manual 3 2 4 Standard Wiring of Sep Ex and Shunt Motor Controller Precharge Resistor 1KQ 10W aq ssm uq pwed M AAT EURI JUU UM M 155 0 0 pal pjald 541 00 Wq Jo md AN Buum Jaqjo Awe AM P MII asvalg NV 8541 03 AMOIYL AS 0 10 SAL 03 INOM PaAQSINY MS 0 LA ALON AHA AS 0 5 AT gt K F IIINE ISIAH y E 2 3 Nn Imo L OAS 0 pw q Peg z els YOMG Sj 9 gt ee 5 3 gt XW dasg Figure 6 Sep Ex Motor Controller Standard Wiring 10 Kelly KD Series Motor Controller User s Manual V 3 2 3 2 5 Back Panel Twelve metal bars and a communication port are provided on the back panel of each controller shown as Figure 7 00 0 0 0 0001 PWR MAIN BEEP LED GND TPS2 5V BRK TPS2 SP PWR RLY AN GUT SW AN SW SW Figure 7 Back Panel of all Controllers PWR Controller power supply output MAIN RLY main contactor coil driver BEEP MTR can drive either reverse alarm or Kelly Ampmeter Default is reverse alarm Configured as current meter Kelly Ampmeter positive connect 5V OUT negative to BEEP MTR LED LED anode GND LED cathode and sensor retur
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