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Kelly KDZ Series/PM/Sep-Ex Motor Controller User’s Manual

V 3.3

Kelly KDZ Series / PM / Sep-Ex

Motor Controller User’s Manual

KDZ24200

KDZ48303

KDZ72200

KDZ12400

KDZ24201

KDZ48400

KDZ72201

KDZ12401

KDZ24202

KDZ48401

KDZ72202

KDZ12402

KDZ24203

KDZ48402

KDZ72203

KDZ12403

KDZ24300

KDZ48403

KDZ72300

KDZ24301

KDZ48550

KDZ72301

KDZ24302

KDZ48551

KDZ72302

KDZ24303

KDZ48552

KDZ72303

KDZ24400

KDZ48553

KDZ72400

KDZ24401

KDZ48650

KDZ72401

KDZ24402

KDZ48651

KDZ72402

KDZ24403

KDZ48652

KDZ72403

KDZ48653

KDZ72550

KDZ48200

KDZ72551

KDZ48201

KDZ64400

KDZ72552

KDZ48202

KDZ64401

KDZ72553

KDZ48203

KDZ64403

KDZ72650

KDZ48300

KDZ72651

KDZ48301
KDZ48302

Rev.3.3

Aug. 2013

Содержание KDZ Series

Страница 1: ...2402 KDZ24203 KDZ48402 KDZ72203 KDZ12403 KDZ24300 KDZ48403 KDZ72300 KDZ24301 KDZ48550 KDZ72301 KDZ24302 KDZ48551 KDZ72302 KDZ24303 KDZ48552 KDZ72303 KDZ24400 KDZ48553 KDZ72400 KDZ24401 KDZ48650 KDZ72401 KDZ24402 KDZ48651 KDZ72402 KDZ24403 KDZ48652 KDZ72403 KDZ48653 KDZ72550 KDZ48200 KDZ72551 KDZ48201 KDZ64400 KDZ72552 KDZ48202 KDZ64401 KDZ72553 KDZ48203 KDZ64403 KDZ72650 KDZ48300 KDZ72651 KDZ48301...

Страница 2: ... Wiring and Installation 5 3 1 Mounting the Controller 5 3 2 Connections 7 3 2 1 Front Panel of KDZ Series or PM Motor Controller 7 3 2 2 Standard Wiring of KDZ Series or PM Motor Controller 9 3 2 3 Front Panel of KDZ Sep Ex Motor Controller 13 3 2 4 Standard Wiring of KDZ Sep Ex Motor Controller 15 3 2 5 Communication Port 16 3 3 Installation Checklist 16 Chapter 4 Maintenance 17 4 1 Cleaning 17 ...

Страница 3: ... of Kelly Controls LLC 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 comprehe...

Страница 4: ...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 switch inputs brake switch reversing switch throttle or forward switch Active low 11 3 analog 0 5V inputs that default to throttle input brake in...

Страница 5: ...etecting 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 provided Easy to use No cost to customers 2 3 Specifications Frequency of Operation 16 6kHz Standby Battery Current 0 5mA Controller power supply current PWR ...

Страница 6: ...nt compound can be used to improve heat conduction from the case to the mounting surface The case outline and mounting holes dimensions are shown in Figure 1 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 Ele...

Страница 7: ...Kelly KDZ Series PM Sep Ex Motor Controller User s Manual V 3 3 6 Height 62 millimeters Figure 1 KDZ mounting holes dimensions dimensions in millimeters ...

Страница 8: ...re 2 Front panel of KDZ motor controller B battery positive and armature positive B battery negative M armature negative J1 Pin Definition 1 12V output 40mA Optional 2 Kelly Current meter 200mA 3 Main contactor driver 2A 4 Alarm To drive reverse beeper 200mA 5 RTN Signal return 6 Green LED Running indication 7 RTN Signal return 8 Reserved Figure 3 The connecting 9 Reserved diagram of J1 and J2 10 ...

Страница 9: ...turn Notes 1 All RTN pins are internally connected 2 Kelly Ammeter positive connect to 5V power supply of controller negative to J1 2 3 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 faults will damage the controller Ensure that the B wiring is securely and properly connected be...

Страница 10: ...Kelly KDZ Series PM Sep Ex Motor Controller User s Manual V 3 3 9 3 2 2 Standard Wiring of KDZ Series or PM Motor Controller Figure 4 KDZ series motor controller standard wiring ...

Страница 11: ...Kelly KDZ Series PM Sep Ex Motor Controller User s Manual V 3 3 10 Figure 5 KDZ Series motor controller standard wiring without Reversing Contactor ...

Страница 12: ...Kelly KDZ Series PM Sep Ex Motor Controller User s Manual V 3 3 11 Figure 6 KDZ PM motor controller standard wiring ...

Страница 13: ...Kelly KDZ Series PM Sep Ex Motor Controller User s Manual V 3 3 12 Figure 7 KDZ PM motor controller standard wiring without Reversing Contactor ...

Страница 14: ...y positive and armature positive B battery negative M armature negative S1 Field positive S2 Field negative S1 and S2 Connect to motor field coil Motor moves forward when current flow from S1 to S2 in the case of REV switch open J1 Pin Definition 1 12V output 40mA Optional 2 Kelly Current meter 200mA 3 Main contactor driver 2mA 4 Alarm To drive reverse beeper 200mA 5 RTN Signal return 6 Green LED ...

Страница 15: ...3 Reserved 14 RTN Signal return Notes 1 All RTN pins are internally connected 2 Kelly Ammeter positive connect to 5V power supply of controller negative to J1 2 3 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 faults will damage the controller Ensure that the B wiring is securel...

Страница 16: ...Kelly KDZ Series PM Sep Ex Motor Controller User s Manual V 3 3 15 3 2 4 Standard Wiring of KDZ Sep Ex Motor Controller Figure 10 KDZ Sep Ex Motor Controller Standard Wiring ...

Страница 17: ... sure 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 ...

Страница 18: ...d B 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 RS2...

Страница 19: ... 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 restart when temperature falls below 80 2 4 Throttle error at power u...

Страница 20: ... 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 flashes once and after a second pause flashes twice The time bet...

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