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Kelly KDHE High Efficient Series/PM Motor Controller User’s Manual

V 3.4

Kelly KDHE High Efficient Series/PM

Motor Controller User’s Manual

KDH72101E
KDH72121E
KDH12401E
KDH12601E
KDH12801E
KDH12101E
KDH12121E
KDH14401E
KDH14601E
KDH14801E

Rev.3.4

Mar. 2021

Summary of Contents for KDH12101E

Page 1: ...eries PM Motor Controller User s Manual V 3 4 Kelly KDHE High Efficient Series PM Motor Controller User s Manual KDH72101E KDH72121E KDH12401E KDH12601E KDH12801E KDH12101E KDH12121E KDH14401E KDH14601E KDH14801E Rev 3 4 Mar 2021 ...

Page 2: ...res 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 Checklist 14 Chapter 4 Maintenance 14 4 1 Cleaning 15 4 2 Configuration 15 Table 1 LED CODES 16 Table 2 Kelly KDHE Controller CAN Commands List 19 Contact Us 23 ...

Page 3: ...center of Kelly Controls 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 boats and industrial motor speed control It uses high power MOSFET s and fast PWM to achieve efficiencies of up to 99 in most cases A powerful microprocessor brings in compre...

Page 4: ...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 supply various kinds of sensors including Hall effect type 10 3 switch inputs which are activated by connection to Ground Default to throttle switch brake switch and rev...

Page 5: ...y installation 1 4V Hall Active throttle or 3 Wire potentiometer 100K can work Standard PC Laptop computer is used to do programming No special tools needed 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 than 2mA Controller supply voltage range PWR 8 to 30V 24V is preferred Control...

Page 6: ...tact 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 and 2 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 off the ground before attempting a...

Page 7: ...PM Motor Controller User s Manual V 3 4 6 Figure 1 Height 84 millimeters Length 204 millimeters Controller models with above dimension KDH72101E KDH72121E KDH12401E KDH12601E KDH12801E KDH12101E KDH12121E KDH14401E KDH14601E KDH14801E ...

Page 8: ...Controller Three metal bars and two plugs J1 J2 are provided for connecting to the battery motor and control signals shown as Figure 3 and Figure 4 Figure 3 Front panel of KDHE motor controller B battery positive and armature positive B battery negative M armature negative Figure 4 Back panel of KDHE motor controller ...

Page 9: ...dication 7 GND Signal return 8 Reserved 9 Reserved 10 CAN bus high Optional 11 CAN bus low Optional 12 Reserved 13 GND Signal return or power supply ground 14 Red LED Fault code J2 Pin Definition 1 PWR Controller power supply input 2 GND Signal return or power supply ground 3 GND Signal return 4 Motor temperature input 5 Throttle analog input 0 5V 6 Brake analog input 0 5V 7 5V 5V supply output 50...

Page 10: ...controller negative to J1 2 4 Switch to ground is active Open switch is inactive 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 ...

Page 11: ...Kelly KDHE High Efficient Series PM Motor Controller User s Manual V 3 4 10 3 2 2 Standard Wiring of KDHE Motor Controller Figure 6 KDHE Series motor controller standard wiring ...

Page 12: ...Kelly KDHE High Efficient Series PM Motor Controller User s Manual V 3 4 11 Figure 7 KDHE Series motor controller standard wiring without Reversing Contactor ...

Page 13: ...Kelly KDHE High Efficient Series PM Motor Controller User s Manual V 3 4 12 Figure 8 KDHE PM motor controller standard wiring ...

Page 14: ...Kelly KDHE High Efficient Series PM Motor Controller User s Manual V 3 4 13 Figure 9 KDHE PM motor controller standard wiring without Reversing Contactor ...

Page 15: ... once and the Green is off After the start up delay normally the Red will stay off and the Green will turn on If there is error the Red LED will flashes for fault codes If the S N less 11xxxxxx Turn on the PWR switch the Red flashes once and the Green is on Normally the Red will stay off If there is error the Red LED will flashes for fault codes The fault code will be detected automatically at res...

Page 16: ... 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 Disconnec...

Page 17: ...n 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 Reduce controller loading or switch Off until controller cools down 2 Clean or improve heatsink or fan 2 2 Internal voltage fault 1 Measure...

Page 18: ... 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 threshold is about 1 25 times of controller rated voltage I e you may set threshold lower than 60V for 48V cont...

Page 19: ...nd CCP_FLASH_READ Length 3 data 0 0xF2 data 1 INFO_MODULE_NAME data 2 8 Controller response Length 8 data 0 data 7 Controller s model in ASCII format 8 bytes Description Getting controller s model no E g 0x4B 0x42 0x4C is K B L 0x30 is 0 INFO_MODULE_NAME constant is defined as 64 Command CCP_FLASH_READ Length 3 data 0 0xF2 data 1 INFO_SOFTWARE_VER data 2 2 Controller response Length 2 data 0 data ...

Page 20: ...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_A2D_BATCH_READ1 Length 1 data 0 0x1b Controller response Length 5 data 0 Brake A D data 1 TPS A D data 2 Operation voltage A D data 3 Vs A D data 4 B A D Description Data batch reading 1 For operation v...

Page 21: ...perature 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_MONITOR2 Length 1 data 0 0x37 Controller response Length 3 data 0 MSB of error code data 1 LSB of error code data 2 present current accounts for percent of the rated cur...

Page 22: ...EADING constant is defined as 0 Command 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 CAN bus rate should be configured to 1Mbit s 2 If the command is out of above commands Controller response Length 1 data 0 CCP_INVALID_COM...

Page 23: ...Kelly KDHE High Efficient Series PM Motor Controller User s Manual V 3 4 22 Contact Us Kelly Controls Home Page http www kellycontroller com E mail support kellycontroller com Phone 01 224 637 5092 ...

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