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Kelly KDZ Series/PM Motor Controller User

’s Manual

V 3.5

0

Kelly KDZ Series / PM

Motor Controller User

’s Manual

KDZ24200

KDZ48300

KDZ72200

KDZ72650E

KDZ24201

KDZ48301

KDZ72201

KDZ72651E

KDZ24300

KDZ48400

KDZ72300

KDZ72800E

KDZ24301

KDZ48401

KDZ72301

KDZ72801E

KDZ24400

KDZ48550

KDZ72400

KDZ12400

KDZ24401

KDZ48551

KDZ72401

KDZ12401

KDZ48200

KDZ48650E

KDZ72550

KDZ48201

KDZ48651E

KDZ72551

Rev.3.5

July, 2022

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Summary of Contents for KDZ72650E

Page 1: ...s Manual KDZ24200 KDZ48300 KDZ72200 KDZ72650E KDZ24201 KDZ48301 KDZ72201 KDZ72651E KDZ24300 KDZ48400 KDZ72300 KDZ72800E KDZ24301 KDZ48401 KDZ72301 KDZ72801E KDZ24400 KDZ48550 KDZ72400 KDZ12400 KDZ24401 KDZ48551 KDZ72401 KDZ12401 KDZ48200 KDZ48650E KDZ72550 KDZ48201 KDZ48651E KDZ72551 Rev 3 5 July 2022 ...

Page 2: ...ifications 4 2 4 Naming Regulations 5 Chapter 3 Wiring and Installation 6 3 1 Mounting the Controller 6 3 2 Connections 9 3 2 1 Front Panel of KDZ Series or PM Motor Controller 9 3 2 2 Standard Wiring of KDZ KDZ E Series or PM Motor Controller 12 3 2 3 Communication Port 16 3 3 Installation Checklist 16 Chapter 4 Maintenance 17 4 1 Cleaning 17 4 2 Configuration 17 Table 1 LED CODES 18 Contact Us 1...

Page 3: ...elly 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 comprehensive and...

Page 4: ...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 supply various kinds of sensors including Hall effect type 10 Multifunctional and configurable 3 switc...

Page 5: ...rk if high throttle is detected at power on Brake switch is used to start regen 0 5V or 0 5K brake signal is used to command regen current Capable of detecting short circuit fault in the main contactor at power on Easy installation 1 4V Hall Active throttle or 0 5K or 0 5V potentiometer 100K can work Standard PC Laptop computer is used to do programming No special tools needed User program provide...

Page 6: ...Kelly KDZ Series PM Motor Controller User s Manual V 3 5 5 2 4 Naming Regulations ...

Page 7: ...on 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 mounting holes dimensions are sho...

Page 8: ...Kelly KDZ Series PM Motor Controller User s Manual V 3 5 7 Height 62 millimeters Figure 1 KDZ mounting holes dimensions dimensions in millimeters ...

Page 9: ...Kelly KDZ Series PM Motor Controller User s Manual V 3 5 8 Height 62 millimeters Figure 2 KDZ E mounting holes dimensions dimensions in millimeters ...

Page 10: ...el of KDZ Series or PM Motor Controller Three metal bars and two plugs J1 J2 are provided for connecting to the battery motor and control signals in the front of the controller shown as Figure 3 and 4 Figure 3 Front panel of KDZ motor controller Figure 4 Front panel of KDZ E motor controller ...

Page 11: ...or power supply ground 14 Red LED Fault code J2 Pin Definition 1 PWR Controller power supply input 2 RTN Signal return or power supply ground 3 RTN Signal return 4 12V high level brake and motor temperature input Demand use KTY84 130 Silicon temperature sensors 5 Throttle analog input 0 5V or 0 5K 6 Brake analog input 0 5V or 0 5K 7 5V 5V supply output 40mA 8 Forward switch input 9 Reversing switc...

Page 12: ...mage 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 the B line All contactors or circuit breakers in the B line must have precharge resistors across their contacts Lack of even one of these precharge resistors may severely damage the controller at switch on ...

Page 13: ...Kelly KDZ Series PM Motor Controller User s Manual V 3 5 12 3 2 2 Standard Wiring of KDZ KDZ E Series or PM Motor Controller Figure 6 KDZ KDZ E series motor controller standard wiring ...

Page 14: ...Kelly KDZ Series PM Motor Controller User s Manual V 3 5 13 Figure 7 KDZ KDZ E Series motor controller standard wiring without Reversing Contactor ...

Page 15: ...Kelly KDZ Series PM Motor Controller User s Manual V 3 5 14 Figure 8 KDZ KDZ E PM motor controller standard wiring ...

Page 16: ...Kelly KDZ Series PM Motor Controller User s Manual V 3 5 15 Figure 9 KDZ KDZ E PM motor controller standard wiring without Reversing Contactor ...

Page 17: ...re 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 Green LED stay on steadily and Red LED turns off 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...

Page 18: ... terminals Remove any dirt or corrosion from the bus bar area The controller should be wiped down with a moist rag Make sure it 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 through either an RS232 ...

Page 19: ...eatsink or fan 2 2 Internal volts fault 1 Measure that B PWR are correct when measured to B or RTN 2 There may be excessive load on the 5V supply caused by too low a value of Regen or throttle potentiometers or incorrect wiring 3 Controller is damaged Contact Kelly about a warranty repair 2 3 Over temperature The controller temperature has exceeded 100 The controller will be stopped but will resta...

Page 20: ...n level is set during configuration 4 2 Field error 1 Field did not reach the configured current 2 Field circuit open Please check field wiring 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 f...

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