Full Text Searchable PDF User Manual
Kelly Full Bridge Permanent Magnet Motor Dc Controller User
’
s Manual
V 1.4
Kelly Full Bridge Permanent Magnet
Dc Motor Controller User
’
s Manual
KPM48401KD
KPM48501KD
KPM72401KD
KPM72501KD
Rev.1.4
April. 2017
Kelly Full Bridge Permanent Magnet Motor Dc Controller User
’
s Manual
V 1.4
1
Contents
Chapter 1 Introduction
.......................................................................................................
2
1.1 Overview
.................................................................................................................
2
Chapter 2 Main Features and Specifications
................................................................
3
2.1 General functions
..................................................................................................
3
2.2 Features
..................................................................................................................
4
2.3 Specifications
.........................................................................................................
4
Chapter 3 Wiring and Installation
.....................................................................................
5
3.1 Mounting the Controller
........................................................................................
5
3.2 Connections
...........................................................................................................
6
3.3 Installation Checklist
...........................................................................................
10
Chapter 4 Maintenance
...................................................................................................
11
4.1 Cleaning
................................................................................................................
11
4.2 Configuration
........................................................................................................
11
Table 1: Error CODES
.....................................................................................................
13
Contact Us:
........................................................................................................................
14
Kelly Full Bridge Permanent Magnet Motor Dc Controller User
’
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V 1.4
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Chapter1
Introduction
1.1 Overview
This manual introduces the Kelly KPM-KD motor controllers
’
features, their installation and
their maintenance. Read the manual carefully and thoroughly before using the controller. If you
have any questions, please contact the support center of Kelly Controls.
Kelly
’
s programmable motor controllers provide efficient, smooth and quiet controls for
electric vehicles like golf carts, go-carts, electric motorcycles, scooters, forklifts and hybrid
vehicles, as well as electric boats and industrial motor speed control. It uses high power
MOSFET
’
s and, PWM to achieve efficiencies of up to 97% in most cases. A powerful
microprocessor brings in comprehensive and precise control to the controllers. It also allows
users to adjust parameters, conduct tests, and obtain diagnostic information quickly and easily.
Kelly
’
s KPM-KD motor controller is full bridge or 4 quadrant controller. It provides fast and
reliable electronic direction control. There is no arc, spark, or life limit on motor direction
changes.
Kelly KPM-KD controller can do programming on PC software or APP in Android Tablet.
Both PC software and Android APP can provide one screen to monitor the controller
parameters.KPM-KD can support Bluetooth connection function by wireless also.Customers
may buy a Bluetooth converter from our website.Customers can do programming and monitor
on Android Phone by using this Bluetooth converter.
KPM-KD has a friendly I/O terminals for customers to hook up the batteries and motor
easily.
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Chapter2 Main Features and Specifications
2.1 General functions
(1) Extended fault detection and protection.Customers can read the error code in PC software
or in Android App also.
(2) Monitoring battery voltage. Stop driving if battery voltage is too high or too low.
(3) Built-in current loop and over current protection.
(4) Configurable motor temperature protection range.
(5) Current cutback at low temperature and high temperature to protect battery and controller.
The current begins to ramp down at 90
℃
case temperature, shutting down at 100
℃
.
(6) Provision of a +5 volt output to supply various kinds of sensors, including Hall effect type.
(7) 4 switch inputs which are activated by connection to Ground. Default to throttle switch, two
speed shift control switch,forward and reversing switch.1 switch input is activated by connection
to 12V which is pin11 of controller.
(8) 3 analog 0-5V inputs that default to throttle input, brake input and motor temperature input.
(9) Meter function:Current meter can display both drive and regen current. Save shunt.
(10) Configurable boost switch. Enables the maximum output power achievable if the switch is
turned on.Boost used the same pin as Brake_AN.Input 5V to activate this function.
(11) Configurable economy switch. Limits the maximum current to half if the switch is turned
on.Economy used the same pin as Brake_AN.Input 5V to activate this function.You can not
enable Boost and Economy function in the user program at the same time.
(12) Configurable speed in reversing direction.
(13) Enhanced regen brake function. A novel ABS technique provides powerful and smooth
regen.The regen can happen at any speeds until zero speed.
(14) Joystick throttle. A bi-symmetrical 0-5V signal for both forwarding and reversing.Can be
enabled or disabled in the user program.
(15) Configurable motor over-temperature detection and protection with the recommended
thermistor KTY84-130/150 or KTY83-122.
(16) Using battery-powered.
(17) KPM-KD controller includes fuse and shunt on the top of the case.
(18) Bluetooth function.Required a small Bluetooth converter which can be purchased from our
website in addition.Customers can use this function to do programming on Android Phone.
(19) Bluetooth converter is only useful for KPM-KD controller.PM controller can not support it.
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2.2 Features
•
Intelligence with powerful microprocessor.
•
Synchronous rectification, ultra low drop, and fast PWM to achieve very high efficiency.
•
Electronic reversing, no reversing contactor needed, fast direction change, high reliability and
efficiency, low noise, no arc, no wearing, no life limit, easy maintenance.
•
Voltage monitoring on voltage source 12V and 5V.
•
Current limit and torque control.
Configurable torque mode and speed mode.
•
Low EMC.
•
Battery protection: current cutback, warning and shutdown at configurable high and low
battery voltage.
•
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.
•
Support three modes of regenerative braking: brake switch regen, release throttle regen,
0-5V analog signal variable regen.
•
Standard PC/Laptop computer or Android Tablet is used to do programming. No special tools
needed.
•
User program provided. Customers can download user program from website for free. No cost
to customers.
www.kellycontroller.com/support.php
2.3 Specifications
•
Frequency of Operation: 16.6KHz.
•
Standby Battery Current: < 0.5mA.
•
5V or 12V Sensor Supply Current: 40mA.
•
Controller supply voltage range, PWR, 18V to B+
•
Supply Current,PWR,30mA Typical.
•
Configurable battery voltage range,B+.Max operating voltage:18V to 1.25*Nominal Voltage.
•
Standard Throttle Input: 0-5 Volts(3-wire resistive pot), 1-4 Volts(hall active throttle).
•
Analog Brake and Throttle Input: 0-5 Volts.
•
Full Power Temperature Range: 0
℃
to 70
℃
(MOSFET temperature).
•
Operating Temperature Range: -40
℃
to 100
℃
(MOSFET temperature).
•
Motor Current Limit, 30s: 400A-500A.depending on the model.
•
Motor Current Limit, continuous:160A-200A, depending on the model.
•
Max Battery Current :Configurable.
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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 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.
Kelly Full Bridge Permanent Magnet DC Motor Controller KPM-KD
Model
30s
Current
Continuous
Current
Rated
Voltage
Voltage Range
Regen
KPM48401KD
400A
160A
48V
24V-48V
Yes
KPM48501KD
500A
200A
48V
24V-48V
Yes
KPM72401KD
400A
160A
72V
24V-72V
Yes
KPM72501KD
500A
200A
72V
24V-72V
Yes
Matching connectors of controller will be shipped for free.
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 circuit.
Kelly Full Bridge Permanent Magnet Motor Dc Controller User
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Figure 1:
mounting holes
’
dimensions (dimensions in millimeters)
3.2 Connections
B+: Battery positive (M8)
B-: Battery negative (M8)
U=M+: armature positive (M8)
V=Null
W=M-: armature negative (M8)
Kelly Full Bridge Permanent Magnet Motor Dc Controller User
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Pin Definition in waterproof connector DJ7091Y-2.3-11/21:
Figure 2: Pin definition in waterproof connectors
(14) REV_SW: Reverse switch input.
Orange
(6) GND: Signal return or power supply return.
Black
(12) FWD: Forward switch
White
(11) 12V:12V Source Red
(19) GND: Signal return.
Black
(22) ECO:Two Shift Speed Control.Dark Blue
(7) PWR: Controller power supply (input).
Pink
(15) Micro_SW: Throttle switch input.
Gray
(3) Throttle: Throttle analog input, 0-5V.
Green
(1) Temp: Motor temperature sensor or low level brake switch.
Raddle.
(20) GND: Signal return.
Black
(8) Meter: Current meter,<200mA
Dark Gray
(25)12V brake switch
. Yellowish
(4) 5V: 5V supply output, <40mA.
Purple
(2) Brake_AN
：
Brake variable regen or Boost function.
Brown
Kelly Full Bridge Permanent Magnet Motor Dc Controller User
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Notes:
1. All GND pins are internally connected.
2. Twist peripheral wires with PWR is the preferred for EMC.
3. Kelly Ammeter positive connect to 5V power supply of controller, negative to pin8.
4. 12V only can be used for Switch or LED wiring, such as 12V brake switch(pin 25).
5. The current meter is installed between pin4 and pin8.Pin4 is going to positive of
current meter,Pin8 is going to negative of current meter.
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 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.
Kelly Full Bridge Permanent Magnet Motor Dc Controller User
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3.2.2 Standard Wiring of KPM-KD Motor Controller
Figure 3: KPM motor controller standard wiring
3.2.2.1 The wiring diagram for low level brake switch function
The Pin1=Temp can be used as low level brake switch also.
3.2.3 Communication Port
A 4pin connector to RS232 converter is provided to communicate with host computer for
calibration and configuration.
Kelly Full Bridge Permanent Magnet Motor Dc Controller User
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Figure 4: SM-4A to DB9(RS232) converter
(Customer may add an USB to RS232 cable in addition)
3.3 Installation Check List
Before operating the vehicle, complete the following checkout procedure. Use Beep Error
code as a reference as listed in Table 1.
Caution:
•
Put the vehicle up on blocks to get the drive wheels off the ground before beginning these
tests.
•
Do not allow anyone to stand directly in front of or behind the vehicle during the checkout.
•
Make sure the PWR switch and the brake is off
•
Use well-insulated tools.
1. Make sure the wire is connected correctly
2. Turn the PWR switch on.
3. The fault code will be detected automatically at restart.
4. With the brake switch open, select a direction and operate the throttle. The motor should
spin in the selected direction. Verify wiring or voltage and the fuse if it does not. The motor
should run faster with increasing throttle. If not, refer to the Table 1 code, and correct the
fault as determined by the fault code.
5. Take the vehicle off the blocks and drive it in a clear area. It should have smooth
acceleration and good power.
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Chapter 4
Maintenance
There are no user-serviceable parts inside the controllers. Do not attempt to open the
controller as this will void your warranty. However, periodic, exterior cleaning of the controller
should be carried out.
The controller is a high powered device. When working with any battery powered vehicle,
proper safety precautions should be taken that include, but are not limited to, proper training,
wearing eye protection, avoidance of loose clothing, hair and jewelry. Always use insulated
tools.
4.1 Cleaning
Although the controller requires virtually no maintenance after properly installation, 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,
resistor or a horn) across the controller
’
s B+ and B- terminals.
•
Remove any dirt 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, if fitted, are tight. To avoid physically stressing
the bus bars use two, well-insulated wrenches.
4.2 Configuration
1,You can configure the controller with a host computer through either an RS232 or USB port.
2,Disconnect motor wiring from controller for configuring existing parameters in the PC user
program or Android APP. If this operation is too much extra job for you, please make sure the
motor must be stopped before programming.
3,The controller may display fault code, but it doesn't affect programming or configuration.
Use a straight through RS232 cable or USB converter provided by Kelly to connect to a host
computer. Provide >+18V to PWR
（
pin7
）
. Wire power supply return(supply negative) to any
RTN pin or B-.
Kelly Full Bridge Permanent Magnet Motor Dc Controller User
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4,KPM-KD controller requires a SM-4A to DB9(RS232) converter besides USB to RS232 cable
to support the communication.And customers may need a Z-TEK USB cable for Tablet with
Android OS.It can support Bluetooth connection in Android Phone if customers use a Bluetooth
converter.
5,The controller may display fault code in some conditions, but it doesn't affect programming or
configuration of KPM-KD controller.
Download the free configuration software from
：
http://www.kellycontroller.com/support.php
Caution:
•
Make certain that the motor is disconnected before trying to run the Configuration
Software!
•
Configuration software will be regularly updated and published on the website. Please
Update your Configuration Software regularly. You must uninstall the older version
before updating.
Kelly Full Bridge Permanent Magnet Motor Dc Controller User
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Table 1:
Beep Error CODES
Beep Error Code
Error Code
Explanation
Solution
Beep keeps sounding
1. Software still upgrading.
2. Supply voltage too low or battery too high
3. The controller is damaged. Contact Kelly about a
warranty repair.
Beep Error Code
1,2
¤
¤¤
Over voltage error
1. Battery voltage is too high for the controller.
Check battery volts and configuration.
2. Regeneration over-voltage. Controller will have
cut back or stopped regen.
3. This only accurate to
±
2% upon 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. Controller case temperature is above 90
℃
.
Current will be limited. Reduce controller
loading or switch Off until controller cools
down.
2. Clean or improve heatsink or fan.
2,2
¤¤
¤¤
Internal volts fault
6. Measure that B+ & PWR are correct when
measured to B- or RTN.
7. There may be excessive load on the +5V
supply caused by too low a value of Regen or
throttle potentiometers or incorrect wiring.
8. 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-up
Throttle signal is higher than the preset
‘
dead zone
’
at Power On. Fault clears when throttle is released.
3,1
¤¤¤ ¤
Frequent reset
May be caused by over-voltage, bad motor
intermittent earthing problem, bad wiring, etc.
3,2
¤¤¤ ¤¤
Internal reset
May be caused by some transient fault condition
like a temporary over-current, momentarily high or
low battery voltage. This can happen during normal
Kelly Full Bridge Permanent Magnet Motor Dc Controller User
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operation.
3,3
¤¤¤ ¤¤¤
Hall throttle is
open or
short-circuit
When the throttle is repaired, a restart will clear the
fault.
3,4
¤¤¤ ¤¤¤¤
Non-zero throttle
on direction
change
Controller won
’
t allow a 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 during regen. The voltage
threshold detection level is set during configuration.
The max threshold is about 1.25 times of controller
rated voltage. I.e. you may set threshold lower than
60V for 48V controller.
4, 3
¤¤¤¤ ¤¤¤
Motor
over-temperature
Motor temperature has exceeded the configured
maximum. The controller will shut down until the
motor temperature cools down.
Customers may read error codes or message in PC software or Android App.
Contact Us:
Kelly Controls
Home Page:
http://www.KellyController.com
Download user manual,instructions and user program:
www.kellycontroller.com/support.php
E-mail:
Phone:
(01) 224 637 5092