Kelly KDS Controllers User Manual
Contents
1. O O Figure 3 Back Panel and SCI Port Figure 4 SCI Converter A SCI port is provided to communicate with RS232 of host computer for calibration and configuration Please note only a special SCI 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 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 Kelly KDS Small Series PM Motor Controller User s Manual V 2 6 Ke ah K_i Junction 1 Male Junction 2 Female Figure 5 Definition of Controller s junction 9 PWR red Controller power supply usually to key switch 1 GND black LED cathode and sensor return 4 Contactor Coil Driver green It s a low side driver Please use PWR as the coil high side 2 LED brown To anode of LED 7 Throttle 5V power source orange 0 5V throttle power input 6 Throttle blue 0 5V throttle input 8 GND black TPS return and switch ground 5 Micro_SW white Close to GND to activate Default as throttle switch Notes All of the above GND pins are internally connected V 2 6 Kelly KDS Small Series2. sure the wire is connected correctly Turn the PWR switch on The LED should blink then stay on steadily when the controller operates normally If this does not happen check continuity of the PWR switch circuit and B connection e The fault code will be detected automatically at restart e Close the switch and operate the throttle The motor should spin If it does not operate check the voltage at controller terminals The motor should run faster with increasing throttle If not refer to Table 1 LED code and correct the fault as determined by the fault code 11 Kelly KDS Small Series PM Motor Controller User s Manual V 2 6 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 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 actually no maintenance after properly installed 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
3. PM Motor Controller User s Manual 3 2 3 Standard Wiring of Series and PM Motor Controller Key Switch Precharge Resistor KO LOW BATTERY YOLOVILNOD ASUAATa g uo aope OI Nd sasay TULA sapo p ApUNIaS andino pasn auena od LON Iua TaMo d AS wonouny 2 109 Figure 6 Series motor controller standard wiring V 2 6 Kelly KDS Small Series PM Motor Controller User s Manual Fuse J 2 gt Z Precharge Resistor KOs LOW BATTERY 9109 nd aaay TULA sapo Aue 9 ana punas aseajd AS D ndino pasn aq uw LON Z uonouny FTLLOMHL TIVH ASO AS ODI Taod AS 2 uonounr LANDVIN LNANVIA Yad Figure 7 PM motor controller standard wiring 10 Kelly KDS Small Series PM Motor Controller User s Manual V 2 6 3 3 Installation Checkout Before operating the motor 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
4. fast PWM to achieve high efficiency Kelly KDS Small Series PM Motor Controller User s Manual V 2 6 Chapter 2 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 the battery voltage is too high or too low 3 Built in current loop and over current protection 4 Current cutback at low temperature and high temperature to protect battery and controller The current begins to ramp down at 90 shutting down at 100 5 0 5V throttle input 2 2 Features e Provision of a 5 volt output to supply various kinds of sensors including Hall effect type e High current metal bar e Small size e Easy to use e Used with PM or series motor e Low cost e Super high efficiency E model available e Intelligence with powerful microprocessor e Synchronous rectification ultra low drop and fast PWM to achieve very high efficiency e Voltage monitoring on voltage source 12V 5V e Current control loop e Hardware over current protection e Support torque mode operation Low EMC 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
5. 100E 100 60 24 36 KDS36200E 200 120 24 36 KDS48050E 50 30 24 48 KDS48100E 100 60 24 48 KDS48200E 200 120 24 48 KDS72050E 50 30 24 72 KDS72100E 100 60 24 72 KDS72200E 200 120 24 72 1 24V model range of the max operating voltage is 8 30V 2 36V model range of the max operating voltage is 18 45V 3 48V model range of the max operating voltage is 18 60V 4 72V model range of the max operating voltage is 18 90V Chapter3 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 screws A thermal joint compound can be used to improve heat conduction from the case to the mounting surface The case outline and mounting holes dimensions are shown in Figure 1 Caution RUNAWAYS Some conditions could cause the motor 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 t
6. Kelly KDS Small Series PM Motor Controller User s Manual V 2 6 Kelly Small Series PM Motor Controller User s Manual Devices Supported KDS24050E KDS24100E KDS24200E KDS36050E KDS36100E KDS36200E KDS48050E KDS48100E KDS48200E KDS72050E KDS72100E KDS72200E Rev 2 6 Oct 2013 Kelly KDS Small Series PM Motor Controller User s Manual V 2 6 Content apter 2 Main Features an eee apter3 iring an nstallat ee 3 3 2 1 Front Panel of Serial or F otor 6 3 2 2 Back Panel of Serial or P otor 7 a tandar Iring eries otor 9 tact E sare ere EC ea A OA Kelly KDS Small Series PM Motor Controller User s Manual V 2 6 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 LLC Kelly s small series PM motor controllers provide efficient smooth and quiet controls for electric tricycles electric motorcycles pump motor and industrial motor speed control It uses high power MOSFET synchronous rectification and
7. by connecting a load such as a contactor coil or a 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 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 12 Kelly KDS Small Series PM Motor Controller User s Manual V 2 6 Table 1 LED CODES LED Code Explanation Solution Off EE No power or 1 Check if all wires are correct switched off 2 Check fuse and power supply switch On 1 Normal operating That s great You got solution 1 2 a Over voltage error 1 Battery voltage is too high for the controller Check battery volts and configuration 2 The controller will clear after 5 seconds if battery volts returns to normal 1 3 ja ann 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 1 4 anon Temperature 1 Controller case temperature is above 90 C warning error 2 Current will be limited Release or reduce throttle until controller cools down 21 an Throttle sensor 1 Check if all wires are correct fault 2 Check if the throttle type is correct 3 Check if the voltage is above 5V when u
8. cut back warning and shutdown at high temperature e Configurable high pedal protection the controller will not work if high throttle is detected at power on Kelly KDS Small Series PM Motor Controller User s Manual V 2 6 2 3 Specifications eMain Contactor Coil Drive 2A 5V Supply Output 30mA Frequency of Operation 16 6kHz Standby Current less than Standard Throttle Input 0 5 Volts 3 wire resistive pot 1 4 Volts hall active throttle Full Power Operating Temperature Range 0 50 controller case temperature Operating Temperature Range 30 to 90 100 c shutdown controller case temperature Peak Current 1 minute 50A 200A depending on the model Continuous current 30A 120A depending the model 2 4 Models The naming regulations of the motor controller model KDS36200E The ninth letter represents some special characteristics E represents high efficiency The sixth seventh and eighth letters represent the max current The fourth and fifth letters represent nominal voltage The first three letters represent Kelly s small series PM motor controller Kelly KDS Small Series PM Motor Controller User s Manual V 2 6 Kelly Small DC Motor Controller Model 1 Minute Current Amp Continuous Current Amp Voltage Volt KDS24050E 50 30 12 24 KDS24100E 100 60 12 24 KDS24200E 200 120 12 24 KDS36050E 50 30 24 36 KDS36
9. ellycontroller com Phone 01 224 637 5092 V 2 6 14
10. ools to prevent short circuit 5 Kelly KDS Small Series PM Motor Controller User s Manual V 2 6 2 o 24 11 78 Sani oft 122 Height 41mm Figure 1 mounting holes dimensions dimensions in millimeters 3 2 Connections 3 2 1 Front Panel of Serial or PM Motor Controller 3 metal bars are provided for connecting to the battery and motor in the front of the controller shown as Figure 2 fo Figure 2 Front panel of Serial or PM Motor Controller M output to armature negative B battery positive and armature positive Kelly KDS Small Series PM Motor Controller User s Manual V 2 6 B battery negative 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 3 2 2 Back Panel of Serial or PM Motor Controller O E x 2 j Kelly SCI Converter www newkellycontroller com
11. se 0 5V hall throttle 4 Check if connects to the right panel conforming to configured throttle type 2 2 an Internal volts fault 1 Measure that B amp PWR correct 2 There may be excessive load on the 5V supply 3 Controller is damaged Contact Kelly about a warranty repair 2 3 an non Over temperature The controller temperature has exceeded 100 C The error controller will be stopped but will restart when temperature falls below 80 C 2 4 aa Throttle error at Throttle signal is higher than the preset dead zone at power on Power On Fault clears when throttle is released 3 1 ana Frequent reset Fault clears after the restart 3 2 ann on 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 ann poo Hall throttle is open When the throttle is repaired a restart will clear the or short circuit fault The LED flashes once at power on as a confidence check and then stays on for normal operation 1 2 means it flashed once and after 0 5 second pause flashes twice The time between two flashes is 0 25 second The pause time between multiple flash code groups is 1 second 13 Kelly KDS Small Series PM Motor Controller User s Manual Contact Us Kelly Controls LLC Home Page http Awww kellycontroller com E mail support k
Download Pdf Manuals
Related Search