KEYA PM24301 User manual

Type
User manual

This manual is also suitable for

Kelly
Kelly
Kelly
Kelly Full
Full
Full
Full Bridge
Bridge
Bridge
Bridge Permanent
Permanent
Permanent
Permanent Magnet
Magnet
Magnet
Magnet Motor
Motor
Motor
Motor Dc
Dc
Dc
Dc Controller
Controller
Controller
Controller User
User
User
User ’
’ s
s
s
s Manual
Manual
Manual
Manual V
V
V
V 3.
3.
3.
3. 2
2
2
2
Kelly
Kelly
Kelly
Kelly Full
Full
Full
Full Bridge
Bridge
Bridge
Bridge Permanent
Permanent
Permanent
Permanent Magnet
Magnet
Magnet
Magnet
Dc
Dc
Dc
Dc Motor
Motor
Motor
Motor Controller
Controller
Controller
Controller User
User
User
User
s
s
s
s Manual
Manual
Manual
Manual
Rev. 3. 2
Oct. 200 9
PM24101
PM24101
PM24101
PM24101
PM24201
PM24201
PM24201
PM24201
PM24
PM24
PM24
PM24 3
3
3
3 01
01
01
01
PM
PM
PM
PM 36
36
36
36 101
101
101
101
PM
PM
PM
PM 36
36
36
36 2
2
2
2 01
01
01
01
PM48101
PM48101
PM48101
PM48101
PM48
PM48
PM48
PM48 2
2
2
2 01
01
01
01
PM48
PM48
PM48
PM48 3
3
3
3 01
01
01
01
PM48
PM48
PM48
PM48 4
4
4
4 01
01
01
01 B
B
B
B
PM48
PM48
PM48
PM48 5
5
5
5 01
01
01
01 B
B
B
B
PM72101
PM72101
PM72101
PM72101
PM72
PM72
PM72
PM72 2
2
2
2 01
01
01
01
PM72
PM72
PM72
PM72 3
3
3
3 01
01
01
01
PM72401
PM72401
PM72401
PM72401 B
B
B
B
PM72501
PM72501
PM72501
PM72501 B
B
B
B
PM72
PM72
PM72
PM72 6
6
6
6 01
01
01
01 B
B
B
B
PM
PM
PM
PM 12151H
12151H
12151H
12151H
PM
PM
PM
PM 12251H
12251H
12251H
12251H
PM
PM
PM
PM 12271H
12271H
12271H
12271H
PM
PM
PM
PM 12401H
12401H
12401H
12401H
Kelly
Kelly
Kelly
Kelly Full
Full
Full
Full Bridge
Bridge
Bridge
Bridge Permanent
Permanent
Permanent
Permanent Magnet
Magnet
Magnet
Magnet Motor
Motor
Motor
Motor Dc
Dc
Dc
Dc Controller
Controller
Controller
Controller User
User
User
User ’
’ s
s
s
s Manual
Manual
Manual
Manual V
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Page 1
Contents
Contents
Contents
Contents
Chapter 1 Introduction ............................................................................................ 2
1.1 Overview ..................................................................................................... 2
Chapter 2 Main Features and Specifications ..........................................................3
2.1 General functions ........................................................................................3
2.2 Features ...................................................................................................... 4
2.3 Specifications ..............................................................................................4
Chapter 3 Wiring and Installation ............................................................................6
3.1 Mounting the Controller .............................................................................. 6
3.2 Connections ................................................................................................ 8
3.3 Installation Check list ................................................................................. 1 2
Chapter 4 Maintenance .........................................................................................1 3
4.1 Cleaning ....................................................................................................1 3
4.2 Configuration .............................................................................................1 3
Table 1: LED CODES ............................................................................................1 4
Contact Us: ........................................................................................................... 1 6
Kelly
Kelly
Kelly
Kelly Full
Full
Full
Full Bridge
Bridge
Bridge
Bridge Permanent
Permanent
Permanent
Permanent Magnet
Magnet
Magnet
Magnet Motor
Motor
Motor
Motor Dc
Dc
Dc
Dc Controller
Controller
Controller
Controller User
User
User
User ’
’ s
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Chapter1
Chapter1
Chapter1
Chapter1 Introduction
Introduction
Introduction
Introduction
1.1
1.1
1.1
1.1 Overview
Overview
Overview
Overview
The manual introduce s Kelly PM motor controller s
features, installation and maintenance.
R ead the manual carefully and thoroughly before us ing 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 quite control s for
electrical vehicles like golf cart, go-cart, electric motorcycle, scooter, fork lift, hybrid vehicle , as
well as electric boat and industry motor speed control. It uses high power MOSFET, PWM to
achieve efficiency 99% in most cases. Powerful microprocessor brings in comprehensive and
precise control to the controllers. It also allow s users to set 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 i s no arc, spark, or life limit on motor direction
changes.
Kelly
Kelly
Kelly
Kelly Full
Full
Full
Full Bridge
Bridge
Bridge
Bridge Permanent
Permanent
Permanent
Permanent Magnet
Magnet
Magnet
Magnet Motor
Motor
Motor
Motor Dc
Dc
Dc
Dc Controller
Controller
Controller
Controller User
User
User
User ’
’ s
s
s
s Manual
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Chapter2
Chapter2
Chapter2
Chapter2 Main
Main
Main
Main Features
Features
Features
Features and
and
and
and Specifications
Specifications
Specifications
Specifications
2.1
2.1
2.1
2.1 General
General
General
General functions
functions
functions
functions
(1)
Extended fault detection and protection. LED flashing code i ndicate s 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)
Controller
s temperature measurement and protection
(5)
Cut ting back c urrent at low temperature and high temperature to protect battery and
controller. The current will ramp down quickly if controller temperature is higher than 90 ,
and shut down at 100
.
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 5V sensor supply
.
(9) 3 switch inputs : Default to throttle switch, brake switch and reverse switch. Clos ing to ground
is to activate .
(10) 3 analog inputs, 0-5V : Default to throttle input, brake input and motor temperature input .
(11)
Reverse alarm output. Recirculation diodes provided.
(12) Main c ontactor driver. Cut off the power if any fault is detected
.
(13) Current meter to display both drive and regen current. Save shunt.
(14) Configurable b oost switch
.
Output can arrive at the maximum current if the switch is
enable d and turned on.
(15) Configurable t urbo switch
.
Limit max power to half if the switch is enable d 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 forward ing 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.
(22) Optional CAN bus.
(23) Optional supply voltage 8V- 3
0V.
Kelly
Kelly
Kelly
Kelly Full
Full
Full
Full Bridge
Bridge
Bridge
Bridge Permanent
Permanent
Permanent
Permanent Magnet
Magnet
Magnet
Magnet Motor
Motor
Motor
Motor Dc
Dc
Dc
Dc Controller
Controller
Controller
Controller User
User
User
User ’
’ s
s
s
s Manual
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2.2
2.2
2.2
2.2 Features
Features
Features
Features
Intelligence with powerful microprocessor.
Synchronous rectification, ultra low drop, and fast PWM to achieve very high efficiency.
Current limit and torque control. Configurable torque mode and speed mode.
Low EMC.
• LED fault code help s user debugging.
Battery protection: Current cutback, shutdown and warning at low battery.
R ugged aluminum housing for maximum heat dissipation.
Thermal protection: Current cut s back at low temperature and high temperature to protect
battery and controller.
High pedal protection: Disable operation if power up with non-zero throttle.
Brake switch is used to start regen.
Able to control and change the motor
s running direction directly.
• Full Programmable with RS-232. Software upgradeable. Free Windows GUI software.
Three modes of regen: brake switch regen, release throttle regen, 0-5V signal regen.
• No adjustment.
2.3
2.3
2.3
2.3 Specifications
Specifications
Specifications
Specifications
Frequency of Operation: 16.6kHz.
Standby Battery Current: < 1 mA.
5V Sensor Supply Current: 40mA.
Supply Voltage, PWR, 18V to B+ ( 8 V to 30V for Controllers r ated equal 24 V )
Supply Current, PWR,150mA.
Standard Throttle Input: 0-5 Volts. P roduc ing 0-5V signal with 3- wire pot .
Analog Brake and Throttle Input: 0-5 Volts.
Reverse Alarm, Main C ontactor Coil Driver, Meter.
• Full Power Temperature Range: 0 to 50 (controller case temperature).
• Operating Temperature Range: -30 to 90 , 100 s hutdown (controller case temperature).
Motor Current Limit , 1 minutes: 100A - 6 0 0A.depending on model.
Motor Current Limit , continuous: 40 A-2 4 0A , depending on model.
Max Battery Current : Configurable .
Kelly
Kelly
Kelly
Kelly Full
Full
Full
Full Bridge
Bridge
Bridge
Bridge Permanent
Permanent
Permanent
Permanent Magnet
Magnet
Magnet
Magnet Motor
Motor
Motor
Motor Dc
Dc
Dc
Dc Controller
Controller
Controller
Controller User
User
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Kelly Full Bridge Permanent Magnet DC Motor Controller
Model
1 minute
C urrent
C ontinuous
C urrent
Rated
Voltage
Voltage
Range
PM24101
100A
40A
24V
12 V- 24 V
PM24201
200A
80A
24V
12 V- 24 V
PM24301
300A
120A
24V
12 V- 24 V
PM 36 101
100A
40A
36 V
24 V- 36 V
PM 36 201
200A
80A
36 V
24 V- 36 V
PM48101
100A
40A
48V
24 V- 48 V
PM48201
200A
80A
48V
24 V- 48 V
PM48 3 01
3 00A
12 0A
48V
24 V- 48 V
PM48401 B
400A
160A
48V
24 V- 48 V
PM48501 B
500A
200A
48V
24 V- 48 V
PM72101
100A
40A
72V
24 V- 72 V
PM72201
200A
80A
72V
24 V- 72 V
PM72 3 01
3 00A
12 0A
72V
24 V- 72 V
PM72401 B
400A
160A
72V
24 V- 72 V
PM72501 B
500A
200A
72V
24 V- 72 V
PM72 6 01 B
6 00A
2 4 0A
72V
24 V- 72 V
PM
12 15
1H
15 0 A
6 0A
120V
24 V- 120 V
PM 122
5
1H
2 5 0 A
1 0 0A
120V
24 V- 120 V
PM 12271H
270 A
11
0A
120V
24 V- 120 V
PM 12 40 1H
40 0 A
1 6 0A
120V
24 V- 120 V
Female plugs of J1&J2 will be shipped for free.
Kelly
Kelly
Kelly
Kelly Full
Full
Full
Full Bridge
Bridge
Bridge
Bridge Permanent
Permanent
Permanent
Permanent Magnet
Magnet
Magnet
Magnet Motor
Motor
Motor
Motor Dc
Dc
Dc
Dc Controller
Controller
Controller
Controller User
User
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’ s
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Chapter
Chapter
Chapter
Chapter 3
3
3
3 Wiring
Wiring
Wiring
Wiring and
and
and
and Installation
Installation
Installation
Installation
3.1
3.1
3.1
3.1 Mounting
Mounting
Mounting
Mounting the
the
the
the Controller
Controller
Controller
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 hole s
dimensions are shown in Figure 1.
Caution:
Caution:
Caution:
Caution:
RUNAWAYS
RUNAWAYS
RUNAWAYS
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
HIGH
HIGH
HIGH CURRENT
CURRENT
CURRENT
CURRENT ARCS
ARCS
ARCS
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 .
Kelly
Kelly
Kelly
Kelly Full
Full
Full
Full Bridge
Bridge
Bridge
Bridge Permanent
Permanent
Permanent
Permanent Magnet
Magnet
Magnet
Magnet Motor
Motor
Motor
Motor Dc
Dc
Dc
Dc Controller
Controller
Controller
Controller User
User
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Height : 62 millimeters
Figure
Figure
Figure
Figure 1:
1:
1:
1: mounting hole s dimensions ( dimensions in millimete rs )
Height : 62 millimeters
Figure
Figure
Figure
Figure 2
2
2
2 :
:
:
:PM-H/B mounting hole s dimensions ( dimensions in millimeter s)
Kelly
Kelly
Kelly
Kelly Full
Full
Full
Full Bridge
Bridge
Bridge
Bridge Permanent
Permanent
Permanent
Permanent Magnet
Magnet
Magnet
Magnet Motor
Motor
Motor
Motor Dc
Dc
Dc
Dc Controller
Controller
Controller
Controller User
User
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’ s
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3.2
3.2
3.2
3.2 Connections
Connections
Connections
Connections
3.2.1
3.2.1
3.2.1
3.2.1 Front
Front
Front
Front Panel
Panel
Panel
Panel of
of
of
of PM
PM
PM
PM Motor
Motor
Motor
Motor Controller:
Controller:
Controller:
Controller:
F our metal bars and two plugs (J1, J2) are provided for connecti ng to the battery, motor
and control signals in the front of the controller shown as Figure 3 .
Figure
Figure
Figure
Figure 3
3
3
3 :
:
:
:Front panel of PM motor controller
B+:
B+:
B+:
B+: Ba
Ba
Ba
Ba ttery
ttery
ttery
ttery positive
positive
positive
positive
B-:
B-:
B-:
B-: Battery
Battery
Battery
Battery negative
negative
negative
negative
M
M
M
M +
+
+
+ :
:
:
: armature
armature
armature
armature positive
positive
positive
positive
M
M
M
M -
-
-
- :
:
:
: armature
armature
armature
armature negative
negative
negative
negative
Figure
Figure
Figure
Figure 4
4
4
4 :
:
:
: The
The
The
The connecting
connecting
connecting
connecting diagram
diagram
diagram
diagram of
of
of
of J1
J1
J1
J1 and
and
and
and J2
J2
J2
J2
J1
J1
J1
J1 Pin
Pin
Pin
Pin Definition
Definition
Definition
Definition
1-
1-
1-
1- PWR
PWR
PWR
PWR :
:
:
: Control
Control
Control
Control ler
ler
ler
ler power
power
power
power supply
supply
supply
supply (output).
(output).
(output).
(output). The
The
The
The pin
pin
pin
pin is
is
is
is
Red
Red
Red
Red LED
LED
LED
LED for
for
for
for S/N
S/N
S/N
S/N less:
less:
less:
less: 08XXXXXX
08XXXXXX
08XXXXXX
08XXXXXX .
.
.
.
2-
2-
2-
2- Current
Current
Current
Current meter
meter
meter
meter <200mA.
<200mA.
<200mA.
<200mA.
3-
3-
3-
3- Main
Main
Main
Main contactor
contactor
contactor
contactor driver
driver
driver
driver <
<
<
< 4
4
4
4 00mA.
00mA.
00mA.
00mA.
4-
4-
4-
4- Alarm:
Alarm:
Alarm:
Alarm: To
To
To
To drive
drive
drive
drive reverse
reverse
reverse
reverse beeper.
beeper.
beeper.
beeper. <200mA
<200mA
<200mA
<200mA
5-
5-
5-
5- RTN:
RTN:
RTN:
RTN: Signal
Signal
Signal
Signal return
return
return
return
6-
6-
6-
6- Green
Green
Green
Green LED:
LED:
LED:
LED: Running
Running
Running
Running indication
indication
indication
indication
7-
7-
7-
7- RTN:
RTN:
RTN:
RTN: Signal
Signal
Signal
Signal return
return
return
return
8-
8-
8-
8- RS232
RS232
RS232
RS232 receiv
receiv
receiv
receiv er
er
er
er
9-
9-
9-
9- RS232
RS232
RS232
RS232 transmitt
transmitt
transmitt
transmitt er
er
er
er
10-
10-
10-
10- CAN
CAN
CAN
CAN bus
bus
bus
bus high
high
high
high
11-
11-
11-
11- CAN
CAN
CAN
CAN bus
bus
bus
bus low
low
low
low
12-
12-
12-
12- Reserved
Reserved
Reserved
Reserved
13-
13-
13-
13- RTN:
RTN:
RTN:
RTN: Signal
Signal
Signal
Signal r
r
r
r eturn,
eturn,
eturn,
eturn, or
or
or
or power
power
power
power supply
supply
supply
supply return
return
return
return
14-
14-
14-
14- Red
Red
Red
Red LED:
LED:
LED:
LED: F
F
F
F ault
ault
ault
ault code
code
code
code .
.
.
. The
The
The
The pin
pin
pin
pin is
is
is
is PWR
PWR
PWR
PWR for
for
for
for S/N
S/N
S/N
S/N less:
less:
less:
less: 08XXXXXX
08XXXXXX
08XXXXXX
08XXXXXX .
.
.
.
Kelly
Kelly
Kelly
Kelly Full
Full
Full
Full Bridge
Bridge
Bridge
Bridge Permanent
Permanent
Permanent
Permanent Magnet
Magnet
Magnet
Magnet Motor
Motor
Motor
Motor Dc
Dc
Dc
Dc Controller
Controller
Controller
Controller User
User
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J2
J2
J2
J2 Pin
Pin
Pin
Pin Definition
Definition
Definition
Definition
1-
1-
1-
1- PWR
PWR
PWR
PWR :
:
:
: Control
Control
Control
Control ler
ler
ler
ler power
power
power
power supply
supply
supply
supply (input)
(input)
(input)
(input)
2-
2-
2-
2- RTN:
RTN:
RTN:
RTN: Signal
Signal
Signal
Signal r
r
r
r eturn,
eturn,
eturn,
eturn, or
or
or
or power
power
power
power supply
supply
supply
supply ground
ground
ground
ground
3-
3-
3-
3- RTN:
RTN:
RTN:
RTN: Signal
Signal
Signal
Signal r
r
r
r eturn
eturn
eturn
eturn
4-
4-
4-
4- Motor
Motor
Motor
Motor temperature
temperature
temperature
temperature input.
input.
input.
input.
5-
5-
5-
5- Throttle
Throttle
Throttle
Throttle analog
analog
analog
analog input,
input,
input,
input, 0-5V
0-5V
0-5V
0-5V
6-
6-
6-
6- B
B
B
B rake
rake
rake
rake analog
analog
analog
analog input
input
input
input ,
,
,
, 0-5V
0-5V
0-5V
0-5V
7-
7-
7-
7- 5V
5V
5V
5V supply
supply
supply
supply output
output
output
output .<40mA
.<40mA
.<40mA
.<40mA
8-
8-
8-
8- Micro_SW:
Micro_SW:
Micro_SW:
Micro_SW: Throttle
Throttle
Throttle
Throttle switch
switch
switch
switch input
input
input
input
9-
9-
9-
9- R
R
R
R everse
everse
everse
everse switch
switch
switch
switch input
input
input
input
10-
10-
10-
10- Brake
Brake
Brake
Brake switch
switch
switch
switch input
input
input
input
11-
11-
11-
11- Reserved
Reserved
Reserved
Reserved
12-
12-
12-
12- Reserved
Reserved
Reserved
Reserved
13-
13-
13-
13- Reserved
Reserved
Reserved
Reserved
14-
14-
14-
14- RTN:
RTN:
RTN:
RTN: Signal
Signal
Signal
Signal r
r
r
r eturn
eturn
eturn
eturn
Notes:
Notes:
Notes:
Notes:
1.
1.
1.
1. All
All
All
All RTN
RTN
RTN
RTN pins
pins
pins
pins are
are
are
are internally
internally
internally
internally connected.
connected.
connected.
connected.
2.
2.
2.
2. Two
Two
Two
Two PWR
PWR
PWR
PWR pins,
pins,
pins,
pins, J1-
J1-
J1-
J1- 1
1
1
1 and
and
and
and J2-1,
J2-1,
J2-1,
J2-1, are
are
are
are internally
internally
internally
internally connected.
connected.
connected.
connected. It
It
It
It ’
’ s
s
s
s recommended
recommended
recommended
recommended to
to
to
to use
use
use
use J1-
J1-
J1-
J1-
1
1
1
1 to
to
to
to supply
supply
supply
supply peripherals
peripherals
peripherals
peripherals like
like
like
like alarm
alarm
alarm
alarm and
and
and
and contactor
contactor
contactor
contactor .
.
.
. Twist
Twist
Twist
Twist peripheral
peripheral
peripheral
peripheral wires
wires
wires
wires with
with
with
with PWR
PWR
PWR
PWR is
is
is
is
the
the
the
the preferred
preferred
preferred
preferred for
for
for
for EMC.
EMC.
EMC.
EMC. Recirculation
Recirculation
Recirculation
Recirculation diodes
diodes
diodes
diodes are
are
are
are provided
provided
provided
provided in
in
in
in the
the
the
the controller
controller
controller
controller to
to
to
to PWR
PWR
PWR
PWR for
for
for
for
alarm
alarm
alarm
alarm and
and
and
and Contactor
Contactor
Contactor
Contactor coil
coil
coil
coil driver.
driver.
driver.
driver.
3.
3.
3.
3. Kelly
Kelly
Kelly
Kelly Ampmeter
Ampmeter
Ampmeter
Ampmeter positive
positive
positive
positive connect
connect
connect
connect to
to
to
to 5V
5V
5V
5V power
power
power
power supply
supply
supply
supply of
of
of
of controller,
controller,
controller,
controller, negative
negative
negative
negative to
to
to
to J1-2.
J1-2.
J1-2.
J1-2.
4.
4.
4.
4. Switch
Switch
Switch
Switch to
to
to
to ground
ground
ground
ground is
is
is
is active.
active.
active.
active. Open
Open
Open
Open switch
switch
switch
switch is
is
is
is inactive
inactive
inactive
inactive .
.
.
.
Caution:
Caution:
Caution:
Caution: Make
Make
Make
Make sure
sure
sure
sure all
all
all
all connections
connections
connections
connections are
are
are
are correct
correct
correct
correct before
before
before
before apply
apply
apply
apply ing
ing
ing
ing power.
power.
power.
power. O
O
O
O therwise
therwise
therwise
therwise it
it
it
it may
may
may
may
damage
damage
damage
damage the
the
the
the controller!
controller!
controller!
controller! Please
Please
Please
Please securely
securely
securely
securely wire
wire
wire
wire B-
B-
B-
B- before
before
before
before applying
applying
applying
applying power.
power.
power.
power. It's
It's
It's
It's preferred
preferred
preferred
preferred to
to
to
to place
place
place
place
contactor
contactor
contactor
contactor or
or
or
or breaker
breaker
breaker
breaker on
on
on
on B+.Please
B+.Please
B+.Please
B+.Please place
place
place
place precharge
precharge
precharge
precharge resistor
resistor
resistor
resistor on
on
on
on any
any
any
any breaker!
breaker!
breaker!
breaker! It
It
It
It can
can
can
can cause
cause
cause
cause
damage
damage
damage
damage without
without
without
without it!!!
it!!!
it!!!
it!!!
Kelly
Kelly
Kelly
Kelly Full
Full
Full
Full Bridge
Bridge
Bridge
Bridge Permanent
Permanent
Permanent
Permanent Magnet
Magnet
Magnet
Magnet Motor
Motor
Motor
Motor Dc
Dc
Dc
Dc Controller
Controller
Controller
Controller User
User
User
User ’
’ s
s
s
s Manual
Manual
Manual
Manual V
V
V
V 3.
3.
3.
3. 2
2
2
2
Page 10
3.2.2
3.2.2
3.2.2
3.2.2 Standard
Standard
Standard
Standard Wiring
Wiring
Wiring
Wiring of
of
of
of PM
PM
PM
PM Motor
Motor
Motor
Motor Controlle
Controlle
Controlle
Controlle r
r
r
r
Figure
Figure
Figure
Figure 5
5
5
5 :
:
:
: PM
PM
PM
PM motor
motor
motor
motor controller
controller
controller
controller standard
standard
standard
standard wiring
wiring
wiring
wiring
Kelly
Kelly
Kelly
Kelly Full
Full
Full
Full Bridge
Bridge
Bridge
Bridge Permanent
Permanent
Permanent
Permanent Magnet
Magnet
Magnet
Magnet Motor
Motor
Motor
Motor Dc
Dc
Dc
Dc Controller
Controller
Controller
Controller User
User
User
User ’
’ s
s
s
s Manual
Manual
Manual
Manual V
V
V
V 3.
3.
3.
3. 2
2
2
2
Page
11
Figure
Figure
Figure
Figure 6
6
6
6 :
:
:
: 120V
120V
120V
120V motor
motor
motor
motor controller
controller
controller
controller standard
standard
standard
standard wiring
wiring
wiring
wiring
Kelly
Kelly
Kelly
Kelly Full
Full
Full
Full Bridge
Bridge
Bridge
Bridge Permanent
Permanent
Permanent
Permanent Magnet
Magnet
Magnet
Magnet Motor
Motor
Motor
Motor Dc
Dc
Dc
Dc Controller
Controller
Controller
Controller User
User
User
User ’
’ s
s
s
s Manual
Manual
Manual
Manual V
V
V
V 3.
3.
3.
3. 2
2
2
2
Page 12
3.2.3
3.2.3
3.2.3
3.2.3 Communication
Communication
Communication
Communication Port
Port
Port
Port
A
RS232 port of controller is provided to communicate with host computer for calibration and
configuration.
Figure
Figure
Figure
Figure 7
7
7
7 :
:
:
:standard RS232 interface
3.3
3.3
3.3
3.3 Installation
Installation
Installation
Installation Checklist
Checklist
Checklist
Checklist
Before operating the vehicle, complete the following checkout procedure s
.
Use LED code
as a reference. The LED codes are listed in
T
able 1 .
Make sure the wire is connected correctly .
Turn the PWR switch on. T he LED should blink, then keep on when the controller operate s
normally. If this does not happen, check continuity of the PWR and controller ground.
T he 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 area. It should have smooth
acceleration and good top speed.
Caution:
Caution:
Caution:
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 both the PWR switch and the brake are off.
Use well-insulated tools .
Kelly
Kelly
Kelly
Kelly Full
Full
Full
Full Bridge
Bridge
Bridge
Bridge Permanent
Permanent
Permanent
Permanent Magnet
Magnet
Magnet
Magnet Motor
Motor
Motor
Motor Dc
Dc
Dc
Dc Controller
Controller
Controller
Controller User
User
User
User ’
’ s
s
s
s Manual
Manual
Manual
Manual V
V
V
V 3.
3.
3.
3. 2
2
2
2
Page 13
Chapter
Chapter
Chapter
Chapter 4
4
4
4 Maintenance
Maintenance
Maintenance
Maintenance
There are no user-serviceable parts inside the controllers. Do not attempt to open the
controller , or will void warranty. However, clea n ing 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
4.1
4.1
4.1 Cleaning
Cleaning
Cleaning
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
4.2
4.2
4.2 Configuration
Configuration
Configuration
Configuration
You can configure the controller with a host computer through RS232 or USB port .
Use straight through RS232 cable or USB converter provide d by Kelly to connect the D9
connector to a host computer. Provide >18V (either J2 pin1 or J1 pin 1 ) to PWR. Wire
power supply return to any RTN pin.
Do not connect B+, throttle and so on. The controller may display fault code, but it doesn't
affect programming or configuration .
Download and setup the configuration software
http://www.newkellycontroller.com/support.php
http://www.newkellycontroller.com/support.php
http://www.newkellycontroller.com/support.php
http://www.newkellycontroller.com/support.php
Kelly
Kelly
Kelly
Kelly Full
Full
Full
Full Bridge
Bridge
Bridge
Bridge Permanent
Permanent
Permanent
Permanent Magnet
Magnet
Magnet
Magnet Motor
Motor
Motor
Motor Dc
Dc
Dc
Dc Controller
Controller
Controller
Controller User
User
User
User ’
’ s
s
s
s Manual
Manual
Manual
Manual V
V
V
V 3.
3.
3.
3. 2
2
2
2
Page 14
Table
Table
Table
Table 1:
1:
1:
1: LED
LED
LED
LED CODES
CODES
CODES
CODES
Green LED Code
Red LED Code
LED Code
Explanation
S olution
Green O ff
No power or no t
operating
1. Check if all wires are correct .
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.
1,2
¤ ¤¤
O ver voltage error
1.
Battery voltage is higher than max operating
voltage of the controller. P lease check the
battery voltage and configuration.
2.
Over voltage at regeneration. Controller will cut
back or s top regeneration .
3.
Please note there could be 2% error with
Overvoltage setting.
1,3
¤ ¤¤¤
Low voltage error
1.
The controller will attempt to clear the fault
code automatically after 5 second if battery
voltage return s to normal.
2.
Check the battery voltage .
3.
C harge battery if necessary.
1,4
¤ ¤¤¤¤
Over t emperature
warning
1.
The controller temperature is over 90 . The
controller will cut back current in the case.
S top or reduce output to ensure the
temperature fall.
2.
Improve heat sink or airflow
2,2
¤¤ ¤¤
I nternal voltage
fault
1.
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
¤¤ ¤¤¤
O ver temperature
1.
When controller
s temperature is over 100 . it
will s top driving in order to protect itself.
2.
Stop driving and wait for temperature fall. T he
controller will restart if temperature drops below
Kelly
Kelly
Kelly
Kelly Full
Full
Full
Full Bridge
Bridge
Bridge
Bridge Permanent
Permanent
Permanent
Permanent Magnet
Magnet
Magnet
Magnet Motor
Motor
Motor
Motor Dc
Dc
Dc
Dc Controller
Controller
Controller
Controller User
User
User
User ’
’ s
s
s
s Manual
Manual
Manual
Manual V
V
V
V 3.
3.
3.
3. 2
2
2
2
Page 15
80.
2,4
¤¤ ¤¤¤¤
Throttle error at
power up
1.
The throttle signal is higher than configured
dead z o ne at power-on .
2.
The fault will disappear if restart s or release s
throttle.
3,1
¤¤¤ ¤
Frequent reset
1. It can be caused by over current, bad motor,
bad ground wiring or so.
3,2
¤¤¤ ¤¤
Internal r eset
Reset caused by over current, h igh battery voltage
or low supply voltage . I t is normal if occurs
occasionally.
3,3
¤¤¤ ¤¤¤
Throttle short or
open circuit when
using 1-4v hall
sensor throttle
1.
Check whether the throttle is short or open up.
2.
When the throttle is normal, restart will clear
the error.
3,4
¤¤¤ ¤¤¤¤
Throttle isn ’ t zero
when try to
change direction
The controller won ’ t change drive direction if
throttle isn ’ t zero. Also it won ’ t change direction at
high speed. The controller will wait throttle and
speed close
to
zero before chang ing direction.
4,1
¤¤¤¤ ¤
Over voltage at
startup or
regeneration
The controller won ’ t drive motor if detect s
overvoltage at power up. It will cut back regen
current or stop regen if detect s overvoltage during
regen.
You
may set overvoltage threshold with GUI .
The max threshold is about 1.25 times of
controller rated voltage. I.e. you may set threshold
lower than 60V for 48V controller.
4, 3
¤¤¤¤ ¤¤¤
M otor over
temperature
1.The motor temperature is higher than configured
max temperature. Controller will s hut down and
wait for motor temperature drop ping.
2.Can change the temperature setting with
configuration program.
T he Red LED flashes once at power on, then keeps o ff for normal operation . “ 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.
Kelly
Kelly
Kelly
Kelly Full
Full
Full
Full Bridge
Bridge
Bridge
Bridge Permanent
Permanent
Permanent
Permanent Magnet
Magnet
Magnet
Magnet Motor
Motor
Motor
Motor Dc
Dc
Dc
Dc Controller
Controller
Controller
Controller User
User
User
User ’
’ s
s
s
s Manual
Manual
Manual
Manual V
V
V
V 3.
3.
3.
3. 2
2
2
2
Page 16
Contact
Contact
Contact
Contact Us:
Us:
Us:
Us:
Kelly
Kelly
Kelly
Kelly Controls,
Controls,
Controls,
Controls, LLC
LLC
LLC
LLC
Home
Home
Home
Home Page:
Page:
Page:
Page:
http://www. new kellycontroller.com
E-mail:
E-mail:
E-mail:
E-mail:
support@kellycontroller.com
Phone:
Phone:
Phone:
Phone:
( 0 1) 224 637 5092
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