Kelly Motor Controller
Contents
1. 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 Its recommended to use J1 1 to supply peripherals like alarm and contactor Twist peripheral wires with PWR is the preferred for EMC 3 Kelly Ammeter positive connect to 5V power supply of controller negative to J1 2 4 Switch to ground is active Open switch is inactive 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 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 V3 3 User s Manual Precharge Resistor 1KQ 10W 3 2 2 Standard Wiring of PM Motor Controller paonpad aq ssamyysiig pued juo g GITP AIT VTIS Ue IUO NOx Tay AY O TFSALM uray st 10 5 19 1 lt q pavmndodap st NFI yearq 10 0 2 1 02 ynd 1919 Sum ypo Ame 910191 g att ipm ased 5912. 10 A1ussad aM ust mdm ayesgq 911 1 pasn aq we 10 9 104 ILON 110400 Wad 951954 Battery Fuse 5 CAT W745 y Switch Diode 200V 3 Main Contactor Fuse LNANVIVEAd 10 Figure 5 PM motor controller standard wiring V3 3 Full Bridge Permanent Magnet Motor Dc Controller User s Manual Precharge Resistor nel 120V Battery Pack Panpa aq ssamyqsuq pued yuoy GITP ATI LTI ue 29 02 NOA May O TFSALM Inep uray st 10 5 iq pavmdodsp st NFD Yearq 10 2 02 md PAN SULIT po Ame 210193 g aw 1 255 ased 91 101 1 55929 ust mdm syerq IJI mndino pasn aq Wed 9 9 9104 ILON tI NIG pawuasay CI TNY9 H NY9 XL TETSU 6 XETETSU 8 NILIY 4 INOI As 0 LIA AS 0 3A Diode 200V LANDVIV LININFIVN 4d Figure 6 120V motor controller standard wiring 11 User s Manual V3 3 3 2 3 Communication Port A RS232 port of controller is provided to communicate with host computer for calibration and configuration 9 Figure 7 standard RS232 interface 3 3 Installation Checklist Before operating the vehicle complete the fo
3. M B mounting holes dimensions dimensions in millimeters User s Manual V3 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 AS 100 TO Ji Pin Definition gL E O 1 PWR Controller power supply output The pin is 14 12 3 Red LED for S N less O O 13 G 2 2 Current meter lt 200mA 8 O 4 3 Main contactor driver lt 2A O O 4 Alarm drive reverse beeper lt 200mA Ss 6 Oo Sa 5 RTN Signal return ha 6 Green LED Running indication 7 RTN Signal return Full Bridge Permanent Magnet Motor Dc Controller User s Manual V 3 3 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 J2 Pin Definition 1 PWR Controller power supply input 2 RTN Signal return 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
4. PWR 150mA Standard Throttle Input 0 5 Volts 8 wire resistive pot 1 4 Volts hall active throttle e Analog Brake and Throttle Input 0 5 Volts e Reverse Alarm Main Contactor Coil Driver Meter Full Power Temperature Range OC to 50C controller case temperature Operating Temperature Range 30C to90C 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 e Max Battery Current Configurable Full Bridge Permanent Magnet Motor Dc Controller User s Manual V 3 3 1 minute Continuous Voltage Model Giant C rr nt Rated Voltage Ler 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 120V Yes PM12201H 200A 80A 120V 24V 120V Yes Female plugs of J1 amp J2 will be shipped for free V 3 3 Chapter 3 Wiring and Installation 3 1 Mounting t
5. gh 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 e Discharge the capacitors in the controller by connecting a load such as a contactor coil resistor or a horn across the controllers 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 e 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 Use straight through RS232 cable or USB Converter provided by Kelly to connect to a host computer Provide gt 18V either J2 pin1 or J1 pin1 to PWR Wire power supply return to any RTN pin 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 programmi
6. he Controller The controller can be oriented in any position which should be as clean and dry as possible and 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 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 Caution e 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 e 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 Full Bridge Permanent Magnet Motor Dc Controller User s Manual V 9 9 T Height 62 millimeters Figure 1 mounting holes dimensions dimensions in millimeters OO r 26 130 146 21 5 114 5 114 215 272 304 Height 62 millimeters Figure 2 P
7. llowing checkout procedures Use LED code as a reference as listed in Table 1 Caution e 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 e Make sure the wire is connected correctly e Turn the PWR switch on The Green LED stay on steadily and Red LED turns off when the controller operates normally If this does not happen check continuity of the PWR and controller ground e 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 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 e Take the vehicle off the blocks and drive it in a clear area It should have smooth acceleration and good top speed 12 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 hi
8. maintenance Read the manual carefully and thoroughly before using the controller Our 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 boats 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 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 The LED flashing pattern indicates the 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 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 C case temperature shutting down at 100C 6 Two RS232 ports Both ca
9. n be used for configuration 7 An RS232 port allows for configuration programming and software upgrades using the free Windows GUI with your PC 8 Provision of a 5 volt output to supply various kinds of sensors including Hall effect type 9 3 switch inputs which are activated by connection to Ground Default to throttle switch brake switch and reversing switch 10 3 analog 0 5V inputs that default to throttle input brake input and motor temperature input 11 Pulsed reverse alarm output 12 Main contactor driver Cutting off the power if any fault is detected 13 Current meter can 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 temperature 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 Optional supply voltage 8V 30V V 3 3 2 2 Features e Intelligence with powerful micro
10. n or improve heatsink or fan N 2 2 no no Internal volts fault 1 Measure that B amp PWR are correct when 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 ooo 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 an onnan Throttle error at power up Throttle signal is higher than the preset dead zone at Power On Fault clears when throttle is released 3 1 noo a Frequent reset May be caused by over voltage bad motor intermittent earthing problem bad wiring etc 1 4 V 3 3 Full Bridge Permanent Magnet Motor Dc Controller User s Manual 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 3 noo non Hall throttle is When the throttle is repaired a restart will clear the open or fault short circuit 3 4 ene uann 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 nnna n Regen or Start up Motor drive is di
11. ng or configuration 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 User s Manual V 3 3 Table 1 Green LED Code LED CODES LED Code Explanation Solution Green Off No power or 1 Check if all wires are correct switched off 2 Check fuse and power supply Green On Normal operation _ That s great You got solution Green amp Red are both On 1 Software still upgrading 2 Supply voltage too low or battery too high 3 The controller is damaged Contact Kelly about a warranty repair Red LED Code 12 e an 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 1 3 a ooo Low voltage error 1 The controller will clear after 5 seconds if battery volts returns to normal 2 Check battery volts amp recharge if required Over temperature warning Controller case temperature is above 90 C Current will be limited Reduce controller loading or switch Off until controller cools down Clea
12. processor e Synchronous rectification ultra low drop and fast PWM to achieve very high efficiency e Electronic reversing no reversing contactor needed fast direction change high reliability and efficiency low noise no arc no wearing no life limit easy maintenance e Voltage monitoring on voltage source 12V and 5V e Current limit and torque control Configurable torque mode and speed mode Low EMC LED fault code e Battery protection current cutback warning and shutdown at configurable high and low battery voltage e Rugged aluminum housing for maximum heat dissipation and harsh environment e 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 regen eSupport three modes of regenerative braking brake switch regen release throttle regen 0 5V analog signal variable regen Standard PC Laptop computer is used to do programming No special tools needed User program provided Easy to use No cost to customers adjustment 2 3 Specifications e Frequency of Operation 16 6 e Standby Battery Current lt 0 5mA 5V Sensor Supply Current 40mA Controller supply voltage range PWR 18V to B 8V to 30V for Controllers rated equal 24V e Supply Current
13. sabled 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 non 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 stays Off 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 JWT Greatway Electric Limited www igreatway com Email info igreatway com 15
14. www igreatway com Email info igreatway com 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 Dec 2012 Full Bridge Permanent Magnet Motor Dc Controller User s Manual V 3 3 Contents Chapter Niess a a 2 2 Chapter 2 Main Features and 3 2 T General 3 22 TOUS shh Sia Oe A 4 2 3 OCC INI CATIONS sree ice ca rrctass icc eae erecta atid ta sata lec cal are tale te tac nee ede 4 Chapter 3Witing and Installations 2 sissstrsee eooeeanceeeiseees 6 3 1 Mounting the ete else areenelias 6 392 CONNECCION AM ee Oka ga 8 3 3 Installation CheCkliStei cg cceee ile ee ee a Oe Ao eee Se Satie 12 Chapter 4 IWMainionian er ce eee 13 A AN aac alata dat 19 4 2 Configuratio M se 19 Tablet 14 15 User s Manual V3 3 Chapter1 Introduction 1 1 Overview This manual introduces the Our PM motor controllers features their installation and their
Download Pdf Manuals
Related Search