Kelly KPM48401KD User manual

KellyFullBridgePermanentMagnetMotorDcControllerUser sManual V1.4

KellyFullBridgePermanentMagnet

DcMotorControllerUser sManual

KPM48401KD

KPM48501KD

KPM72401KD

KPM72501KD

Rev.1.4

April.2017

KellyFullBridgePermanentMagnetMotorDcControllerUser sManual V1.4

Contents

Chapter1Introduction.......................................................................................................2

1.1Overview.................................................................................................................2

Chapter2MainFeaturesandSpecifications................................................................ 3

2.1Generalfunctions..................................................................................................3

2.2Features..................................................................................................................4

2.3Specifications.........................................................................................................4

Chapter3WiringandInstallation.....................................................................................5

3.1MountingtheController........................................................................................5

3.2Connections...........................................................................................................6

3.3InstallationChecklist...........................................................................................10

Chapter4Maintenance...................................................................................................11

4.1Cleaning................................................................................................................11

4.2Configuration........................................................................................................11

Table1:ErrorCODES.....................................................................................................13

ContactUs:........................................................................................................................14

KellyFullBridgePermanentMagnetMotorDcControllerUser sManual V1.4

Chapter1 Introduction

1.1Overview

ThismanualintroducestheKellyKPM-KDmotorcontrollers features,theirinstallationand

theirmaintenance.Readthemanualcarefullyandthoroughlybeforeusingthecontroller.Ifyou

haveanyquestions,pleasecontactthesupportcenterofKellyControls.

Kelly sprogrammablemotorcontrollersprovideefficient,smoothandquietcontrolsfor

electricvehicleslikegolfcarts,go-carts,electricmotorcycles,scooters,forkliftsandhybrid

vehicles,aswellaselectricboatsandindustrialmotorspeedcontrol.Ituseshighpower

MOSFETsand,PWMtoachieveefficienciesofupto97%inmostcases.Apowerful

microprocessorbringsincomprehensiveandprecisecontroltothecontrollers.Italsoallows

userstoadjustparameters,conducttests,andobtaindiagnosticinformationquicklyandeasily.

Kelly sKPM-KDmotorcontrollerisfullbridgeor4quadrantcontroller.Itprovidesfastand

reliableelectronicdirectioncontrol.Thereisnoarc,spark,orlifelimitonmotordirection

changes.

KellyKPM-KDcontrollercandoprogrammingonPCsoftwareorAPPinAndroidTablet.

BothPCsoftwareandAndroidAPPcanprovideonescreentomonitorthecontroller

parameters.KPM-KDcansupportBluetoothconnectionfunctionbywirelessalso.Customers

maybuyaBluetoothconverterfromourwebsite.Customerscandoprogrammingandmonitor

onAndroidPhonebyusingthisBluetoothconverter.

KPM-KDhasafriendlyI/Oterminalsforcustomerstohookupthebatteriesandmotor

easily.

KellyFullBridgePermanentMagnetMotorDcControllerUser sManual V1.4

Chapter2MainFeaturesandSpecifications

2.1Generalfunctions

(1)Extendedfaultdetectionandprotection.CustomerscanreadtheerrorcodeinPCsoftware

orinAndroidAppalso.

(2)Monitoringbatteryvoltage.Stopdrivingifbatteryvoltageistoohighortoolow.

(3)Built-incurrentloopandovercurrentprotection.

(4)Configurablemotortemperatureprotectionrange.

(5)Currentcutbackatlowtemperatureandhightemperaturetoprotectbatteryandcontroller.

Thecurrentbeginstorampdownat90 casetemperature,shuttingdownat100 .

(6)Provisionofa+5voltoutputtosupplyvariouskindsofsensors,includingHalleffecttype.

(7)4switchinputswhichareactivatedbyconnectiontoGround.Defaulttothrottleswitch,two

speedshiftcontrolswitch,forwardandreversingswitch.1switchinputisactivatedbyconnection

to12Vwhichispin11ofcontroller.

(8)3analog0-5Vinputsthatdefaulttothrottleinput,brakeinputandmotortemperatureinput.

(9)Meterfunction:Currentmetercandisplaybothdriveandregencurrent.Saveshunt.

(10)Configurableboostswitch.Enablesthemaximumoutputpowerachievableiftheswitchis

turnedon.BoostusedthesamepinasBrake_AN.Input5Vtoactivatethisfunction.

(11)Configurableeconomyswitch.Limitsthemaximumcurrenttohalfiftheswitchisturned

on.EconomyusedthesamepinasBrake_AN.Input5Vtoactivatethisfunction.Youcannot

enableBoostandEconomyfunctionintheuserprogramatthesametime.

(12)Configurablespeedinreversingdirection.

(13)Enhancedregenbrakefunction.AnovelABStechniqueprovidespowerfulandsmooth

regen.Theregencanhappenatanyspeedsuntilzerospeed.

(14)Joystickthrottle.Abi-symmetrical0-5Vsignalforbothforwardingandreversing.Canbe

enabledordisabledintheuserprogram.

(15)Configurablemotorover-temperaturedetectionandprotectionwiththerecommended

thermistorKTY84-130/150orKTY83-122.

(16)Usingbattery-powered.

(17)KPM-KDcontrollerincludesfuseandshuntonthetopofthecase.

(18)Bluetoothfunction.RequiredasmallBluetoothconverterwhichcanbepurchasedfromour

websiteinaddition.CustomerscanusethisfunctiontodoprogrammingonAndroidPhone.

(19)BluetoothconverterisonlyusefulforKPM-KDcontroller.PMcontrollercannotsupportit.

KellyFullBridgePermanentMagnetMotorDcControllerUser sManual V1.4

2.2Features

•Intelligencewithpowerfulmicroprocessor.

•Synchronousrectification,ultralowdrop,andfastPWMtoachieveveryhighefficiency.

•Electronicreversing,noreversingcontactorneeded,fastdirectionchange,highreliabilityand

efficiency,lownoise,noarc,nowearing,nolifelimit,easymaintenance.

•Voltagemonitoringonvoltagesource12Vand5V.

•Currentlimitandtorquecontrol. Configurabletorquemodeandspeedmode.

•LowEMC.

•Batteryprotection:currentcutback,warningandshutdownatconfigurablehighandlow

batteryvoltage.

•Thermalprotection:currentcutback,warningandshutdownathightemperature.

•Configurablehighpedalprotection:thecontrollerwillnotworkifhighthrottleisdetectedat

poweron.

•Supportthreemodesofregenerativebraking:brakeswitchregen,releasethrottleregen,

0-5Vanalogsignalvariableregen.

•StandardPC/LaptopcomputerorAndroidTabletisusedtodoprogramming.Nospecialtools

needed.

•Userprogramprovided.Customerscandownloaduserprogramfromwebsiteforfree.Nocost

tocustomers.

www.kellycontroller.com/support.php

2.3Specifications

•FrequencyofOperation:16.6KHz.

•StandbyBatteryCurrent:<0.5mA.

•5Vor12VSensorSupplyCurrent:40mA.

•Controllersupplyvoltagerange,PWR,18VtoB+

•SupplyCurrent,PWR,30mATypical.

•Configurablebatteryvoltagerange,B+.Maxoperatingvoltage:18Vto1.25*NominalVoltage.

•StandardThrottleInput:0-5Volts(3-wireresistivepot),1-4Volts(hallactivethrottle).

•AnalogBrakeandThrottleInput:0-5Volts.

•FullPowerTemperatureRange:0

to70 (MOSFETtemperature).

•OperatingTemperatureRange:-40 to100 (MOSFETtemperature).

•MotorCurrentLimit,30s:400A-500A.dependingonthemodel.

•MotorCurrentLimit,continuous:160A-200A,dependingonthemodel.

•MaxBatteryCurrent:Configurable.

KellyFullBridgePermanentMagnetMotorDcControllerUser sManual V1.4

Chapter3WiringandInstallation

3.1MountingtheController

Thecontrollercanbeorientedinanypositionwhichshouldbeascleananddryaspossible,

andifnecessary,shieldedwithacovertoprotectitfromwaterandcontaminants.

Toensurefullratedoutputpower,thecontrollershouldbefastenedtoaclean,flatmetal

surfacewithfourscrews.Applyingsilicongreaseorsomeotherthermalconductivematerialto

contactsurfacewillenhancethermalperformance.

Properheatsinkingandairflowarevitaltoachievethefullpowercapabilityofthe

controller.

Thecaseoutlineandmountingholes dimensionsareshowninFigure1.

KellyFullBridgePermanentMagnetDCMotorControllerKPM-KD

Model 30s

Current Continuous

Current Rated

Voltage VoltageRange 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

Matchingconnectorsofcontrollerwillbeshippedforfree.

Caution:

•RUNAWAYS —Someconditionscouldcausethevehicletorunoutofcontrol.Disconnect

themotor,orjackupthevehicle,andgetthedrivewheelsoffthegroundbefore

attemptinganyworkonthemotorcontrolcircuitry.

•HIGHCURRENTARCS —Electricvehiclebatteriescansupplyveryhighpower,andarcs

canoccuriftheyareshortcircuit.Alwaysturnoffthebatterycircuitbeforeworkingonthe

motorcontrolcircuit.Wearsafetyglasses,anduseproperlyinsulatedtoolstoprevent

shortcircuit.

KellyFullBridgePermanentMagnetMotorDcControllerUser sManual V1.4

Figure1: mountingholes dimensions(dimensionsinmillimeters)

3.2Connections

B+:Batterypositive(M8)

B-:Batterynegative(M8)

U=M+:armaturepositive(M8)

V=Null

W=M-:armaturenegative(M8)

KellyFullBridgePermanentMagnetMotorDcControllerUser sManual V1.4

PinDefinitioninwaterproofconnectorDJ7091Y-2.3-11/21:

Figure2:Pindefinitioninwaterproofconnectors

(14)REV_SW:Reverseswitchinput. Orange

(6)GND:Signalreturnorpowersupplyreturn. Black

(12)FWD:Forwardswitch White

(11)12V:12VSourceRed

(19)GND:Signalreturn. Black

(22)ECO:TwoShiftSpeedControl.DarkBlue

(7)PWR:Controllerpowersupply(input). Pink

(15)Micro_SW:Throttleswitchinput. Gray

(3)Throttle:Throttleanaloginput,0-5V. Green

(1)Temp:Motortemperaturesensororlowlevelbrakeswitch. Raddle.

(20)GND:Signalreturn. Black

(8)Meter:Currentmeter,<200mA DarkGray

(25)12Vbrakeswitch.Yellowish

(4)5V:5Vsupplyoutput,<40mA. Purple

(2)Brake_AN BrakevariableregenorBoostfunction. Brown

KellyFullBridgePermanentMagnetMotorDcControllerUser sManual V1.4

Notes: 1.AllGNDpinsareinternallyconnected.

2.TwistperipheralwireswithPWRisthepreferredforEMC.

3.KellyAmmeterpositiveconnectto5Vpowersupplyofcontroller,negativetopin8.

4.12VonlycanbeusedforSwitchorLEDwiring,suchas12Vbrakeswitch(pin25).

5.Thecurrentmeterisinstalledbetweenpin4andpin8.Pin4isgoingtopositiveof

currentmeter,Pin8isgoingtonegativeofcurrentmeter.

Caution:

•Donotapplypoweruntilyouarecertainthecontrollerwiringiscorrectandhasbeen

doublechecked.Wiringfaultswilldamagethecontroller.

•EnsurethattheB-wiringissecurelyandproperlyconnectedbeforeapplyingpower.

•ThepreferredconnectionofthesystemcontactororcircuitbreakerisinserieswiththeB+

line.

•AllcontactorsorcircuitbreakersintheB+linemusthaveprechargeresistorsacrosstheir

contacts.Lackofevenoneoftheseprechargeresistorsmayseverelydamagethe

controlleratswitch-on.

KellyFullBridgePermanentMagnetMotorDcControllerUser sManual V1.4

3.2.2StandardWiringofKPM-KDMotorController

Figure3:KPMmotorcontrollerstandardwiring

3.2.2.1Thewiringdiagramforlowlevelbrakeswitchfunction

ThePin1=Tempcanbeusedaslowlevelbrakeswitchalso.

3.2.3CommunicationPort

A4pinconnectortoRS232converterisprovidedtocommunicatewithhostcomputerfor

calibrationandconfiguration.

This manual suits for next models

Table of contents

Popular Controllers manuals by other brands

Digiplex

Digiplex DGP-848 Programming guide

YASKAWA

YASKAWA SGM series user manual

Sinope

Sinope Calypso RM3500ZB installation guide

Isimet

Isimet DLA Series Style 2 Installation, Operations, Start-up and Maintenance Instructions

LSIS

LSIS sv-ip5a user manual

Rockwell Automation

Rockwell Automation 1769-L31 installation instructions

Airflow

Airflow Uno hab Installation and operating instructions

ABB

ABB ACS580-01 drives Hardware manual

Panasonic

Panasonic GM1 Series Reference manual

Emerson

Emerson SW93 owner's manual

AutoAqua

AutoAqua Smart ATO micro SATO-120P manual

Panasonic

Panasonic FP? Positioning Unit RTEX Technical manual

Samson

Samson Type 5824 Mounting and operating instructions

Alpha IP

Alpha IP MIOB 21001 manual

Siemens

Siemens OpenAir GMA 1 Series Mounting instructions

Surecom

Surecom SR-629 user manual

Fishman

Fishman TriplePlay installation guide

Regulus

Regulus SRS1 T Installation and operation manual