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

V 3.4

4

•Low EMC.
•LED fault code.
•Voltage monitoring on voltage source 12V and 5V.
•Hardware over current protection.
•Hardware over voltage protection.
•Support torque mode, speed mode, and balanced mode operation.
•Configurable limit for motor current.
•Battery protection: current cutback, warning and shutdown at configurable high and low

battery voltage.

• Rugged aluminum housing for maximum heat dissipation and harsh environment. Support fan
or water cooling.
•Rugged high current terminals, and rugged aviation connectors for small signal.
•Thermal protection: current cut back, warning and shutdown at high temperature.
•Configurable high pedal protection: the controller will not work if high throttle is detected at

power on.

•Brake switch is used to start regen.
•0-5V brake signal is used to command regen current.
•Easy 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).

Controller input power, PWR: less than 10W.

Configurable battery voltage range, B+. Max operating range: 18V-90V for 72V controllers;

18V-136V for 120V controllers;18V to 180V for 144V controllers.

Standard Throttle Input: 0-5 Volts(3-wire resistive pot), 1-4 Volts(hall active throttle).

Analog Brake and Throttle Input: 0-5 Volts. Producing 0-5V signal with 3-wire pot.

Reverse Alarm, Main Contactor Coil Driver, Meter.

•Full Power Temperature Range: 0

to 50

(controller case temperature).

•Operating Temperature Range: -30

to 90

,100

shutdown (controller case temperature).

•Motor Current Limit,1 minutes: 400A - 1200A, depending on the model.

Motor Current Limit, continuous:180A - 540A, depending on the model.

Содержание KDH72101E

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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