Kelly KDHD Controllers User Manual
Contents
1. Figure 5 Back panel of KDHD motor controller 1 one end of 0 5K potentiometer 2 the other end of 0 5K potentiometer positive supply voltage of controller negative supply voltage of controller SCI SCI port 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 Kelly KDHD High Power Series PM Motor Controller User s Manual V 3 3 3 2 2 Standard Wiring of KDHD Motor Controller Precharge Resistor 2KO0 20W egen Fuse Pol lH 41 Coil Reverse Contactor Led sim Diode 200V 3A Diode 200V 3A n NOT E Please securely wire B before any other wiring Never put contactor or break on B Don t connect 12 V Return to B 10 30V can be used 24V Isolated DCDC Converter Is Preferred Figure 6 KDHD Series motor controller standard wiring Kelly KDHD High Power Series PM Motor Controller User s Manual V 3 3 Precharge Resistor 2KQ 20W Battery UT k m un K 1 N 10 30V can be used 22. Please note only a special SCI Converter provided by Kelly Controls can be used Please use straight RS232 cable to connect with PC 3 3 Installation Checklist 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 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 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 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 Takethe vehicle off the blocks and drive it ina clear area It should have smooth acceleration and good top speed 13 Kelly KDHD High Power Series PM Motor Controller User s Manual V 3 3 Chapter 4 Maintenance There are no user serviceable parts inside the controll
3. Regeneration has braking effect but does not replace the function of a mechanical brake A mechanical brake is required to stop your vehicle Regen IS NOT a safety feature Controller may stop regen without warning to protect itself or the battery it won t protect you 2 2 Features Opto isolated technology achieve stability Intelligence with powerful microprocessor Current limit and torque control sl ow EMC sl ED fault code Voltage monitoring on voltage source 12V and 5V Hardware over current protection Hardware over voltage protection eSupport torque mode speed mode and balanced mode operation Configurable limit for motor current Battery protection current cutback warning and shutdown at configurable high and low battery voltage Rugged aluminum housing for maximum heat dissipation and harsh environment Support fan or water cooling Rugged high current terminals and aviation connectors for small signal 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 3 Kelly KDHD High Power Series PM Motor Controller User s Manual V 3 3 Easy installation 0 5K two wires potentiometer can work User program provided Easy to use No cost to customers 2 3 Specifications Frequency of Operation 16 6kHz Standby Battery Current depending on the model usually less
4. 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 Kelly KDHD High Power Series PM Motor Controller User s Manual V 3 3 162 Figure 1 Height 84 millimeters Length 204 millimeters Controller models with above dimension KDH72800D KDH72100D KDH72120D KDH12400D KDH12600D KDH12800D KDH14400D KDH14600D Kelly KDHD High Power Series PM Motor Controller User s Manual V 3 3 162 Figure 2 Height 84 millimeters Length 286 millimeters Controller models with above dimension KDH12100D KDH12120D KDH14800D KDH14100D KDH14120D Kelly KDHD High Power Series PM Motor Controller User s Manual V 3 3 3 2 Connections 3 2 1 Panel of KDHD Motor Controller Three thick metal bars and four sheetmetals provided for connecting to the battery motor and control signals in the front of the controller shown as Figure 4 and 5 UT E IN V7 ZEN tellt CC H LJ Figure 4 Front panel of KDHD motor controller B battery positive and armature positive B battery negative M armature negative Kelly KDHD High Power Series PM Motor Controller User s Manual V 3 3 amp 0 5K 2 f C7 Kelly Controls LLC
5. than 2mA Controller supply voltage range PWR 8V to 30V 24V is preferred Standard Throttle Input 0 5K 3 wire or 2 wire pot Controller input power PWR less than 10W Configurable battery voltage range B Max operating range 18V to 90V for 72V controllers 18V to 136V for 120V controllers 18V to 180V for 144V controllers Full Power Temperature Range OC to 40C controller case temperature Operating Temperature Range 30C to 90C 100C shutdown controller case temperature Motor Current Limit 1 minutes 400A 1200A depending on the model Motor Current Limit continuous 200A 540A depending on the model 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 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 or six 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 2 and 3 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
6. 4V Isolated DC DC Converter Is Preferre d NOTE Please securely wire B before any other wiring Never put contactor or break on B Don t connect 12V Retum to B Figure 7 KDHD Series motor controller standard wiring without Reversing Contactor 10 V 3 3 Kelly KDHD High Power Series PM Motor Controller User s Manual Precharge Resistor 2KO 20W VE AOQ pauapag s 43142 A00 ML X PREJOS A FZ pasn aque AED A 0 MINNA A ZL 13218109 1 0001 g uo MEA 40 409369102 nd 42 MN Zhu apo Aue 310120 g au pandas asearq LLON z og 4030 4 puey JUIU PUL d Figure 8 KDHD PM motor controller standard wiring 11 Kelly KDHD High Power Series PM Motor Controller User s Manual V 3 3 Precharge Resistor 2KQ 20W Battery ai e a SL x e ES 8 bea E E 10 30V can be used 24V Isolated DC DC Converter Is Preferred NOTE Please securely wire B before any other wiring Never put contactor or break on B Don t connect 12V Retum to B Figure 9 KDHD PM motor controller standard wiring without Reversing Contactor 12 Kelly KDHD High Power Series PM Motor Controller User s Manual V 3 3 3 2 3 Communication Port ac 0 o o 9 O O j Kelly SCI Converter o C CO OO O www newkellycontroller com ed Figure 10 SCI Port on Back Panel Figure 11 SCI Converter A SCI port is provided to communicate with RS232 of host computer for calibration and configuration
7. C warning Current will be limited Reduce controller loading or switch Off until controller cools down Clean or improve heatsink or fan Internal volts fault Measure that B amp PWR are correct when measured to B or RTN There may be excessive load on the 5V supply caused by too low a value of Regen or throttle potentiometers or incorrect wiring Controller is damaged Contact Kelly about a warranty repair 2 3 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 uu anan Throttle error at Throttle signal is higher than the preset dead zone Power up at Power On Fault clears when throttle is released 3 1 nuu n Frequent reset May be caused by over voltage bad motor intermittent earthing problem bad wiring etc 15 Kelly KDHD High Power Series PM Motor Controller User s Manual 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 V 3 3 groups is two seconds Contact Us Kelly Controls LLC Home Page http www kellycontroller com E mail support kellycontroller com Phone 01 224 637 5092 16
8. Kelly KDHD High Power Series PM Motor Controller User s Manual V 3 3 Kelly KDHD High Power Series PM Motor Controller User s Manual KDH72800D KDH72100D KDH72120D KDH12400D KDH12600D KDH12800D KDH12100D KDH12120D KDH14400D KDH14600D KDH14800D KDH14100D KDH14120D Rev 3 3 Aug 2012 Kelly KDHD High Power Series PM Motor Controller User s Manual V 3 3 Contents Chapter 1 Toss les EE 2 TROVE MIE ER Em 2 Chapter 2 Main Features and Specifications sse eee eee eee 3 2 RER ele dee EE 3 22 USS Cm 3 2 9 SOEC IC SHOES scan densae la RE cog ada Fr eV e o ea puis 3 Chapter 3 Wiring and Installation sese eee eee eee 4 3 1 Mounting the Controller usce hate terre eee 4 ou GO dolls dcenetotactved ri teo o terr CUR Pt re eae a e EE dS 6 3 3 Installation GASCKO Ul er 13 Chapter 4 Malnternalncee i irre egene Eegenen 14 zi Re e EE 14 EIERE 14 Table 1 LED Eeer 15 Contact H ccv TD HMM HD ES 16 Kelly KDHD High Power Series PM Motor Controller User s Manual V 3 3 Chapter 1 Introduction 1 1 Overview This manual introduces the Kelly KDHD High Power 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 LLC Kellys programmable motor controllers provide efficient smooth and quiet controls for electric vehicles like golf carts go carts electric motorcycles forklifts and hybrid v
9. ehicles 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 9996 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 KDHD High Power Series PM Motor Controller User s Manual V 3 3 Chapter 2 Main Features and Specifications 2 1 General functions 1 Extended fault detection and protection The Red LED flashing pattern indicates the fault sources and Green LED indicates normal operation Controller will shut down in some fault conditions 2 Monitoring battery voltage It will stop driving if the battery voltage is too high and it will progressively cut back motor drive power as battery voltage drops until it cuts out altogether atthe preset Low Battery Voltage setting 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 100 C 6 Configurable and programmable with a host computer though RS232 or USB Provide free GUI which can run on Windows XP 2000 Windows 7 and Vista recommend using Kelly Standard USB To RS232 Converter 7 Supply voltage 8V 30V Caution
10. ers 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 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 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 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 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 4 2 Configuration You can configure the controller with a host computer either an through RS232 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 programming or configuration e Use a straight
11. through RS232 cable or USB Converter and SCI connect provided by Kelly to connect to a host computer e Provide 10V 30V supply to 12V 12V on controller s back panel The source should be off before programming Download the free configuration software from http www kellycontroller com support php 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 14 Kelly KDHD High Power Series PM Motor Controller User s Manual V 3 3 Table 1 LED CODES Green LED Code LED Code Green Off No power or 1 Check if all wires are correct switched off 2 Check fuse and power supply Normal operation That s great You got solution Green amp Red are 1 Software still upgrading both On 2 Supply voltage too low or battery too high 3 The controller is damaged Contact Kelly about a warranty repair Red LED Code LED Code 12 1 Over voltage error Battery voltage is too high for the controller Check battery volts and configuration This only accurate to 2 upon Overvoltage setting Low voltage error 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
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