background image

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

V 3.4

17

released

2. Set throttle model as "Hall Active" throttle in

GUI if you use that throttle model.

3,1

¤¤¤

¤

Frequent reset

May be caused by over-voltage, bad motor

intermittent earthing problem, bad wiring, etc.

3,2

¤¤¤

¤¤

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

¤¤¤

¤¤¤

Hall throttle is
open or
short-circuit

When the throttle 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 threshold is about 1.25 times of controller

rated voltage. I.e. you may set threshold lower than

60V for 48V controller.

4, 3

¤¤¤¤

¤¤¤

Motor
over-temperature

Motor temperature has exceeded the configured

maximum. The controller will shut down until the

motor temperature cools down.

The Red LED flashes once at power on as a confidence check and then normally

stays Off. “1, 2” means the Red flashes once and after a second pause, flashes twice.
The time between two flashes is 0.5 second. The pause time between multiple flash code
groups is two seconds.

Summary of Contents for KDH72101E

Page 1: ...ries 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 KDH14601...

Page 2: ...es 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 Ch...

Page 3: ...enter 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 vehi...

Page 4: ...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 Pro...

Page 5: ...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...

Page 6: ...act 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 i...

Page 7: ...M 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 KDH121...

Page 8: ...ontroller 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 batte...

Page 9: ...ication 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...

Page 10: ...ontroller 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 fau...

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...

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 i...

Page 17: ...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 Cont...

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...

Page 19: ...d 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...

Page 20: ...ONE_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...

Page 21: ...erature 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 in...

Page 22: ...ADING 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 a...

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...

Reviews: