Kelly KDS24050E User Manual Download Page 1

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Kelly KDS Small Series/PM Motor Controller User

’

s Manual

V 2.7

Kelly Small Series/PM Motor

Controller User’s Manual

Devices Supported:

KDS24050E

KDS24100E

KDS24200E

KDS36050E

KDS36100E

KDS36200E

KDS48050E

KDS48100E

KDS48200E

KDS72050E

KDS72100E

KDS72200E

Rev.2.7

Dec.2016

Summary of Contents for KDS24050E

Page 1: ...ntroller User s Manual V 2 7 Kelly Small Series PM Motor Controller User s Manual Devices Supported KDS24050E KDS24100E KDS24200E KDS36050E KDS36100E KDS36200E KDS48050E KDS48100E KDS48200E KDS72050E KDS72100E KDS72200E Rev 2 7 Dec 2016 ...

Page 2: ...ures 3 2 3 Specifications 4 2 4 Models 4 Chapter3 Wiring and Installation 5 3 1 Mounting the Controller 5 3 2 Connections 6 3 2 1 Front Panel of Serial or PM Motor Controller 6 3 2 2 Back Panel of Serial or PM Motor Controller 7 3 2 3 Standard Wiring of Series and PM Motor Controller 9 3 3 Installation Checkout 11 Chapter 4 Maintenance 12 4 1 Cleaning 12 Table 1 LED CODES 13 Contact Us 14 ...

Page 3: ...the manual carefully and thoroughly before using the controller If you have any questions please contact the support center of Kelly Controls Kelly s small series PM motor controllers provide efficient smooth and quiet controls for electric tricycles electric motorcycles pump motor and industrial motor speed control It uses high power MOSFET synchronous rectification and fast PWM to achieve high e...

Page 4: ...fect type High current metal bar Small size Easy to use Used with PM or series motor Low cost Super high efficiency E model available Intelligence with powerful microprocessor Synchronous rectification ultra low drop and fast PWM to achieve very high efficiency Voltage monitoring on voltage source 12V and 5V Current control loop Hardware over current protection Support torque mode operation Low EM...

Page 5: ...ard Throttle Input 0 5 Volts 3 wire resistive pot 1 4 Volts hall active throttle Full Power Operating Temperature Range 0 to 50 controller case temperature Operating Temperature Range 30 to 90 100 shutdown controller case temperature Peak Current 1 minute 50A 200A depending on the model Continuous current 30A 120A depending on the model 2 4 Models The naming regulations of the motor controller mod...

Page 6: ...r can be oriented in any position which should be as clean and dry as possible and if necessary shielded 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 A thermal joint compound can be used to improve heat conduction from the case to the mounting surface The case outline and mo...

Page 7: ...meters 3 2 Connections 3 2 1 Front Panel of Serial or PM Motor Controller 3 metal bars are provided for connecting to the battery and motor in the front of the controller shown as Figure 2 Figure 2 Front panel of Serial or PM Motor Controller M output to armature negative B battery positive and armature positive B battery negative ...

Page 8: ...everely damage the controller at switch on 3 2 2 Back Panel of Serial or PM Motor Controller Figure 3 Back Panel and SCI Port Figure 4 SCI Converter A SCI port is provided to communicate with RS232 of host computer for calibration and configuration Please note only a special SCI Converter provided by Kelly Controls can be used Please use straight RS232 cable to connect with PC Download the free co...

Page 9: ... sensor return 4 Contactor Coil Driver green It s a low side driver Please use PWR as the coil high side 2 LED brown To anode of LED 7 Throttle 5V power source orange 0 5V throttle power input 6 Throttle blue 0 5V throttle input 8 GND black TPS return and switch ground 5 Micro_SW white Close to GND to activate Default as throttle switch Notes All of the above GND pins are internally connected ...

Page 10: ...Kelly KDS Small Series PM Motor Controller User s Manual V 2 7 9 3 2 3 Standard Wiring of Series and PM Motor Controller Figure 6 Series motor controller standard wiring ...

Page 11: ...Kelly KDS Small Series PM Motor Controller User s Manual V 2 7 10 Figure 7 PM motor controller standard wiring ...

Page 12: ...e the PWR switch and the brake is off Use well insulated tools Make sure the wire is connected correctly Turn the PWR switch on The LED should blink then stay on steadily when the controller operates normally If this does not happen check continuity of the PWR switch circuit and B connection The fault code will be detected automatically at restart Close the switch and operate the throttle The moto...

Page 13: ... and jewelry Always use insulated tools 4 1 Cleaning Although the controller requires actually no maintenance after properly installed 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 or a horn across the controller ...

Page 14: ... if connects to the right panel conforming to configured throttle type 2 2 Internal volts fault 1 Measure that B PWR are correct 2 There may be excessive load on the 5V supply 3 Controller is damaged Contact Kelly about a warranty repair 2 3 Over temperature error The controller temperature has exceeded 100 The controller will be stopped but will restart when temperature falls below 80 2 4 Throttl...

Page 15: ...Kelly KDS Small Series PM Motor Controller User s Manual V 2 7 14 Contact Us Kelly Controls Home Page http www kellycontroller com E mail support kellycontroller com Phone 01 224 637 5092 ...

Page 16: ...Kelly KDS Small Series PM Motor Controller User s Manual V 2 7 15 ...

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