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Kelly HIGH VOLTAGE KHDA Series, User Manual

Introducing the Kelly HIGH VOLTAGE KHDA Series - a revolutionary line of products designed to deliver unparalleled performance. To conveniently access all the necessary information, make sure to download the free User Manual from manualshive.com. This comprehensive manual provides detailed instructions to maximize the potential of your KHDA Series product.

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Kelly

Kelly

Kelly

Kelly KDHA

KDHA

KDHA

KDHA High

High

High

High Voltage

Voltage

Voltage

Voltage Series/PM

Series/PM

Series/PM

Series/PM Motor

Motor

Motor

Motor Controller

Controller

Controller

Controller User

User

User

User’’’’s

s

s

s Manual

Manual

Manual

Manual

V

V

V

V 3.1

3.1

3.1

3.1

Page 9

Figure

Figure

Figure

Figure 4

4

4

4:::: KDH

KDH

KDH

KDHA

A

A

A Series

Series

Series

Series motor

motor

motor

motor controller

controller

controller

controller standard

standard

standard

standard wiring

wiring

wiring

wiring

Summary of Contents for HIGH VOLTAGE KHDA Series

Page 1: ...1 Dec 2008 KDH07600A KDH07600A KDH07600A KDH07600A KDH07601 KDH07601 KDH07601 KDH07601A A A A KDH07800A KDH07800A KDH07800A KDH07800A KDH07801 KDH07801 KDH07801 KDH07801A A A A KDH09400 KDH09400 KDH09400 KDH09400A A A A KDH09401 KDH09401 KDH09401 KDH09401A A A A KDH09 KDH09 KDH09 KDH095 5 5 500 00 00 00A A A A KDH09 KDH09 KDH09 KDH095 5 5 501 01 01 01A A A A KDH12 KDH12 KDH12 KDH124 4 4 400 00 00 ...

Page 2: ...anual Manual Manual V V V V 3 1 3 1 3 1 3 1 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 3 2 3 Specifications 4 Chapter 3 Wiring and Installation 5 3 1 Mounting the Controller 5 3 2 Connections 7 3 3 Installation Checkout 13 Chapter 4 Maintenance 14 4 1 Cleaning 14 4 2 Configurat...

Page 3: ...r features installation and maintenance Read the manual carefully and thoroughly before use the controller Should you have any questions please contact the support center of Kelly Controls LLC Kelly s programmable motor controllers provide efficient smooth and quite controls for electrical vehicles like golf cart go cart electric motorcycle fork lift hybrid vehicle as well as electric boat and ind...

Page 4: ... 7 Configurable to limit max reverse speed to half of max forward speed 8 Configurable and programmable with RS 232 Software upgradeable Windows GUI provided 9 Provide 5V sensor supply 10 3 switch inputs Close to ground to activate Default to throttle switch brake switch and reverse switch 11 3 analog inputs 0 5V Default to throttle input brake input and motor temperature input 12 Reverse alarm ou...

Page 5: ...Limit 10 seconds boost 200A 400A 500A 600A 800A depending on model Motor Current Limit 1 minutes 300A 350A 400A 600A 800A depending on model Motor Current Limit continuous 100A 160A 200A 240A 320A depending on model Kelly High Voltage DC Motor Controller Model 10 seconds boost current 1 minutes current continuous current Nominal Voltage Range Max operating voltage Regen KDH07600A 600A 600A 240A 24...

Page 6: ...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 dimensions are shown in Figure 1 Caution Caution Caution Caution RUNAWAYS RUNAWAYS RUNAWAYS RUNAWAYS Some...

Page 7: ...ries PM Series PM Series PM Series PM Motor Motor Motor Motor Controller Controller Controller Controller User User User User s s s s Manual Manual Manual Manual V V V V 3 1 3 1 3 1 3 1 Page 6 Tall 62 millimeters Figure Figure Figure Figure 1 1 1 1 mounting hole dimensions dimensions in millimeters ...

Page 8: ...1 J1 J1 Pin Pin Pin Pin Definition Definition Definition Definition 1 1 1 1 PWR PWR PWR PWR Control Control Control Controller 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 C...

Page 9: ...o Two PWR PWR PWR PWR pins pins pins pins J1 14 J1 14 J1 14 J1 14 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 14 14 14 14 to to to to supply supply supply supply peripherals peripherals peripherals pe...

Page 10: ...Motor Controller Controller Controller Controller User User User User s s s s Manual Manual Manual Manual V V V V 3 1 3 1 3 1 3 1 Page 9 Figure Figure Figure Figure 4 4 4 4 KDH KDH KDH KDHA A A A Series Series Series Series motor motor motor motor controller controller controller controller standard standard standard standard wiring wiring wiring wiring ...

Page 11: ...User User User s s s s Manual Manual Manual Manual V V V V 3 1 3 1 3 1 3 1 Page 10 Figure Figure Figure Figure 5 KDHA 5 KDHA 5 KDHA 5 KDHA Series Series Series Series motor motor motor motor controller controller controller controller standard standard standard standard wiring wiring wiring wiring without without without without Reversing Reversing Reversing Reversing Contactor Contactor Contactor...

Page 12: ...r Motor Motor Controller Controller Controller Controller User User User User s s s s Manual Manual Manual Manual V V V V 3 1 3 1 3 1 3 1 Page 11 Figure Figure Figure Figure 6 6 6 6 KDH KDH KDH KDHA A A A PM PM PM PM motor motor motor motor controller controller controller controller standard standard standard standard wiring wiring wiring wiring ...

Page 13: ...r User User User User s s s s Manual Manual Manual Manual V V V V 3 1 3 1 3 1 3 1 Page 12 Figure Figure Figure Figure 7 7 7 7 KDH KDH KDH KDHA A A A PM PM PM PM motor motor motor motor controller controller controller controller standard standard standard standard wiring wiring wiring wiring without without without without Reversing Reversing Reversing Reversing Contactor Contactor Contactor Conta...

Page 14: ... Table 1 Make sure the wire is connected correctly Turn the PWR switch on The LED should blink then keeps on 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 Ple...

Page 15: ...ontroller requires virtually no maintenance after properly installation the following minor maintenance is recommended in certain applications Remove power by disconnecting the battery 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 b...

Page 16: ...ry voltage 3 Charge battery if necessary 1 4 Over temperature warning 1 The controller temperature is over 90ºC The controller will cut back current in the case Stop or reduce output to ensure the temperature fall 2 Improve heat sink or airflow 2 1 Throttle sensor fault 1 Check if the connecting is correct 2 Check if the voltage is in 0 5V 2 2 Internal voltage fault 1 Check if the B and PWR voltag...

Page 17: ...rs occasionally 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 change direction 4 1 Over voltage at startup or regeneration The controller won t drive motor if detect overvoltage at power up It will cut back regen cur...

Page 18: ...oller Controller User User User User s s s s Manual Manual Manual Manual V V V V 3 1 3 1 3 1 3 1 Page 17 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 kellycontroller com E mail E mail E mail E mail support kellycontroller com Phone Phone Phone Phone 01 224 637 5092 ...

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