Kelly KDZ72650E User manual

Kelly KDZ Series/PM Motor Controller User’s Manual V 3.5

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

Kelly KDZ Series/PM Motor Controller User’s Manual V 3.5

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

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

Kelly KDZ Series/PM Motor Controller User’s Manual V 3.5

Chapter 1 Introduction

1.1 Overview

This manual introduces the Kelly KDZ Series/PM 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, 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 precise control to the controllers. It also allows users to adjust parameters,

conduct tests, and obtain diagnostic information quickly and easily.

Kelly KDZ Series/PM Motor Controller User’s Manual V 3.5

Chapter 2 Main Features and Specifications

2.1General functions

(1) Extended fault detection and protection. The LED flashing pattern indicates the fault sources.

(2) Monitoring battery voltage. It will stop driving if the battery voltage is too high and it will

progressively cut back motor drive power as battery voltage drops until it cuts out altogether at

the preset “Low Battery Voltage”setting.

(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 90ﹾＣ(controller case temperature), shutting down at 100ﹾＣ.

(6) The controller keeps monitoring battery recharging voltage during regenerative braking,

progressively cutting back current as battery voltage rises then cutting off regen altogether

when voltage goes too high.

(7) Maximum 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 switch inputs: brake switch, reversing switch, throttle or

forward switch. Active low.

(11) 3 analog 0-5V inputs that default to throttle input, brake input and motor temperature input.

(12) Pulsed reverse alarm output.

(13) Maximum reverse power is configurable to half power.

(14) Configurable motor over-temperature detection and protection with the recommended

thermistor KTY84-130/150 or KTY83-122.

(15) Optional 12V output power which can only be applied for Switch signals or LED. Any heavy

load is inhibited.

Caution! Regeneration has braking effect but does not replace the function of a mechanical brake.

A mechanical brake is required to stop your vehicle. Regen IS NOT a safety feature! Controller

may stop regen, without warning, to protect itself or the battery(it won’t protect you!).

Kelly KDZ Series/PM Motor Controller User’s Manual V 3.5

2.2 Features

•Intelligence with powerful microprocessor.

•Synchronous rectification, ultra low drop, and fast PWM to achieve very high efficiency.

•Voltage monitoring on voltage source 12V and 5V.

•Hardware over current protection.

•Hardware over voltage protection.

•Current limit and torque control.

•Low EMC.

•LED fault code.

•Battery protection: current cutback, warning and shutdown at configurable high and low

battery voltage.

•Rugged aluminum housing for maximum heat dissipation and harsh environment.

•Rugged high current terminals, and rugged aviation connectors for small signal.

•Thermal protection: current cut back, warning and shutdown at high temperature.

•Configurable Current-Mode or Voltage-Mode when Field Switch is enabled, to achieve higher

safety and reliability.

•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 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 "HallActive" 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, <150mA.

•Configurable battery voltage range, B+.

•Standard Throttle Input: 0-5K(2-wire resistive pot), 0-5V (3-wire resistive pot), 1-4V (hall active

throttle).

•Analog Brake and Throttle Input: 0-5V or 0-5K.

•Reverse Alarm, Main Contactor Coil Driver, Meter.

•Full Power Temperature Range: 0ﹾＣto 50ﹾＣ(controller case temperature).

•Operating Temperature Range: -30ﹾＣto 90ﹾＣ, 100ﹾＣshutdown (controller case temperature).

•Motor Current Limit, 1 minutes: 200A-800A, depending on the model.

•Motor Current Limit, continuous:80A-320A, depending on the model.

Kelly KDZ Series/PM Motor Controller User’s Manual V 3.5

2.4 Naming Regulations

Kelly KDZ Series/PM Motor Controller User’s Manual V 3.5

Kelly KDZ Brushed DC Series/PM Motor Controller

Model

Peak Current

1 minute (Amp)

Continuous

Current (Amp)

Nominal

Voltage (Volt)

Max Operating

Voltage(Volt)

Regen

KDZ24201

200

12-24

KDZ24301

300

120

12-24

KDZ24401

400

160

12-24

KDZ48201

200

24-48

KDZ48301

300

120

24-48

KDZ48401

400

160

24-48

KDZ48551

550

220

24-48

KDZ48651E

650

260

24-48

KDZ72201

200

24-72

KDZ72301

300

120

24-72

KDZ72401

400

160

24-72

KDZ72551

550

220

24-72

KDZ72651E

650

260

24-72

KDZ72801E

800

320

24-72

KDZ12401

400

160

24-120

136

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. 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 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 circuit.

Kelly KDZ Series/PM Motor Controller User’s Manual V 3.5

Height: 62 millimeters

Figure 1: KDZ mounting holes’ dimensions (dimensions in millimeters)

Kelly KDZ Series/PM Motor Controller User’s Manual V 3.5

Height: 62 millimeters

Figure 2: KDZ-E mounting holes’ dimensions (dimensions in millimeters)

Kelly KDZ Series/PM Motor Controller User’s Manual V 3.5

3.2 Connections

3.2.1 Front Panel 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

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