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

V 3.4

5

Chapter 3 Wiring and Installation

3.1 Mounting the Controller

The controller 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 or six screws. Applying silicon grease or some other thermal conductive
material to contact 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 any work on the motor control circuitry.

• HIGH CURRENT ARCS

Electric vehicle batteries can supply very high power, and

arcs can occur if they are short circuit. Always turn off the battery circuit before
working on the motor control circuit. Wear safety glasses, and use properly
insulated tools to prevent short.

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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