Kelly KDH07121E User Manual Download Page 1 | Manualshive

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Kelly KDH07121E User Manual Download Page 1

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KDH07121E

KDH07121E

KDH07121E

KDH07121E

Rev.3.3

Jan. 2012

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Summary of Contents for KDH07121E

Page 1: ...otor Motor Controller Controller Controller Controller User User User User s s s s Manual Manual Manual Manual KDH07801E KDH07801E KDH07801E KDH07801E KDH07121E KDH07121E KDH07121E KDH07121E KDH12601E KDH12601E KDH12601E KDH12601E KDH12801E KDH12801E KDH12801E KDH12801E KDH12101E KDH12101E KDH12101E KDH12101E KDH KDH KDH KDH12121E 12121E 12121E 12121E KDH12151E KDH12151E KDH12151E KDH12151E KDH121...

Page 2: ...V V V V 3 3 3 3 3 3 3 3 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 4 3 1 Mounting the Controller 4 3 2 Connections 6 3 3 Installation Checklist 13 Chapter 4 Maintenance 14 4 1 Cleaning 14 4 2 Configuration 14 Table 1 LED ...

Page 3: ...es 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 programmable motor controllers provide efficient smooth and quiet controls for electric vehicles like golf carts go carts electric motorcycles forklifts and hybrid vehicles as well as electric boat...

Page 4: ...urrent as battery voltage rises then cutting off regen altogether when voltage goes too high 7 Maximum reverse speed is configurable to half of the maximum forward speed 8 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 9 Provision of a 5 volt output to...

Page 5: ...ications Specifications Frequency of Operation 16 6kHz Standby Battery Current depending on the model usually less than 2mA Controller supply voltage range PWR 8 to 30V 24V is preferred Controller input power PWR less than 10W Configurable battery voltage range B Max operating range 18V 136V for 120V controllers 18V to 180V for 144V controllers Standard Throttle Input 0 5 Volts 3 wire resistive po...

Page 6: ...AWAYS 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 tur...

Page 7: ...imeters Length 286 millimeters Controller models with above dimension KDH12151E KDH12181E KDH14121E KDH14151E KDH14801E KDH14101E 3 2 3 2 3 2 3 2 Connections Connections Connections Connections 3 2 1 3 2 1 3 2 1 3 2 1 Panel Panel Panel Panel of of of of KDH KDH KDH KDHE E E E Motor Motor Motor Motor Controller Controller Controller Controller Three metal bars and two plugs J1 J2 are provided for c...

Page 8: ...cting diagram of J1 J1 J1 J1 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 Controller ler ler ler power power power power supply supply supply supply output output output output 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 contac...

Page 9: ... 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...

Page 10: ...ual Manual Manual V V V V 3 3 3 3 3 3 3 3 Page 9 3 2 3 2 3 2 3 2 2 2 2 2 Standard Standard Standard Standard Wiring Wiring Wiring Wiring of of of of KDHE KDHE KDHE KDHE Motor Motor Motor Motor Controller Controller Controller Controller Figure Figure Figure Figure 6 6 6 6 KDH KDH KDH KDHE E E E Series Series Series Series motor motor motor motor controller controller controller controller standard...

Page 11: ... User User User User s s s s Manual Manual Manual Manual V V V V 3 3 3 3 3 3 3 3 Page 10 Figure Figure Figure Figure 7 7 7 7 KDHE KDHE KDHE KDHE 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 Con...

Page 12: ... Motor Motor Motor Controller Controller Controller Controller User User User User s s s s Manual Manual Manual Manual V V V V 3 3 3 3 3 3 3 3 Page 11 Figure Figure Figure Figure 8 8 8 8 KDH KDH KDH KDHE E E E PM PM PM PM motor motor motor motor controller controller controller controller standard standard standard standard wiring wiring wiring wiring ...

Page 13: ...roller User User User User s s s s Manual Manual Manual Manual V V V V 3 3 3 3 3 3 3 3 Page 12 Figure Figure Figure Figure 9 9 9 9 KDH KDH KDH KDHE E E E 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 ...

Page 14: ... to stand stand stand stand directly directly directly directly in in in in front front front front of of of of or or or or behind behind behind behind the the the the vehicle vehicle vehicle vehicle during during during during the the the the checkout checkout checkout checkout Make Make Make Make sure sure sure sure the the the the PWR PWR PWR PWR switch switch switch switch and and and and the ...

Page 15: ...tion Configuration You can configure the controller with a host computer either an through RS232 Disconnect motor wiring from controller 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 Use a straight through RS232 cable or Kelly USB To RS232 Converter to connect to a host computer Provide 10V 30V either...

Page 16: ...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 Low voltage error 1 The controller will clear after 5 seconds if battery volts returns to normal 2 Check battery volts recharge if required 1 4 Over temperature warning 1 Controller case temperature is above 90 Current will be limited Red...

Page 17: ...is repaired a restart will clear the fault 3 4 Non zero throttle on direction change Controller won t allow a direction change unless the throttle or speed is at zero Fault clears when throttle is released 4 1 Regen or Start up over voltage Motor drive is disabled if an over voltage is detected at start up or during regen The voltage threshold detection level is set during configuration The max th...

Page 18: ...D 115 0x73 It also can be set by configuration program Frame Frame Frame Frame type type type type data frame Length Length Length Length the number of data field bytes Data Data Data Data field field field field The controller sends one or two data frames in response Commands Commands Commands Commands definitions definitions definitions definitions Command CCP CCP CCP CCP_FLASH_READ _FLASH_READ ...

Page 19: ...as 38 Command CCP CCP CCP CCP_FLASH_READ _FLASH_READ _FLASH_READ _FLASH_READ Length 3 data 0 0xF2 data 1 CAL_BRAKE_DEAD_ZONE_HIGH data 2 1 Controller response Length 1 data 0 Brake_Dead_Zone_High Desccription Getting controller s Brake high end dead zone CAL_BRAKE_DEAD_ZONE_HIGH constant is defined as 39 Command CCP CCP CCP CCP_A2D_BATCH_READ _A2D_BATCH_READ _A2D_BATCH_READ _A2D_BATCH_READ1 1 1 1 ...

Page 20: ...on or disabling 1 enable 0 disable 3 data 2 is defined as the temperature of motor in Celsius temperature If the temperature sensor is not connected the controller returns 0xFF 4 data 3 data 5 are defined as controller inside temperature in Celsius temperature The value of data 4 and data 5 are inaccurate below 30 Command CCP CCP CCP CCP_MONITOR _MONITOR _MONITOR _MONITOR2 2 2 2 Length 1 data 0 0x...

Page 21: ... COM_SW_REV COM_SW_REV COM_SW_REV COM_SW_REV Length 2 data 0 0x44 data 0 COM_READING Controller response Length 1 data 0 Current Reverse switch status Description Getting Reverse swith status 1 active 0 inactive COM_READING constant is defined as 0 NOTICE NOTICE NOTICE NOTICE CAN bus rate should be configured to 1Mbit s 2 If the command is out of above commands Controller response Length 1 data 0 ...

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