Kelly KD He User Manual
Kelly KD He User Manual
KDH72801E
KDH72101E
KDH72121E
KDH12401E
KDH12601E
KDH12801E
KDH12101E
KDH12121E
KDH12151E
KDH12181E
KDH14401E
KDH14601E
KDH14801E
KDH14101E
KDH14121E
KDH14151E
Rev.3.3
Dec. 2012
Kelly KDHE High Efficient Series/PM Motor Controller User’s Manual V 3.3
Contents
Chapter 1 Introduction ......................................................................... 2
2.2 Features...................................................................................... 3
4.1 Cleaning.................................................................................... 16
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Kelly KDHE High Efficient Series/PM Motor Controller User’s Manual V 3.3
Chapter 1 Introduction
1.1 Overview
This manual introduces the Kelly KDHE High Efficient 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, 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 comprehensive and precise control to the controllers. It also allows users to adjust
parameters, conduct tests, and obtain diagnostic information quickly and easily.
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Kelly KDHE High Efficient Series/PM Motor Controller User’s Manual V 3.3
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!).
2.2 Features
•Opto-isolated technology achieve stability.
•Intelligence with powerful microprocessor.
•Synchronous rectification, ultra low drop, and fast PWM to achieve very high efficiency.
•Current limit and torque control.
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•Low EMC.
•LED fault code.
•Voltage monitoring on voltage source 12V and 5V.
•Hardware over current protection.
•Hardware over voltage protection.
•Support torque mode, speed mode, and balanced mode operation.
•Configurable limit for motor current.
•Battery protection: current cutback, warning and shutdown at configurable high and low
battery voltage.
• Rugged aluminum housing for maximum heat dissipation and harsh environment. Support fan
or water cooling.
•Rugged high current terminals, and rugged aviation connectors for small signal.
•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.
•Brake switch is used to start regen.
•0-5V brake signal is used to command regen current.
•Easy 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 customers.
2.3 Specifications
•Frequency of Operation: 16.6kHz.
•Standby Battery Current depending on the model: usually less than 2mA.
•Controller supply voltage range, PWR, 8 to 30V(24V is preferred).
•Controller input power, PWR: less than 10W.
•Configurable battery voltage range, B+. Max operating range: 18V-90V for 72V controllers;
18V-136V for 120V controllers;18V to 180V for 144V controllers.
•Standard Throttle Input: 0-5 Volts(3-wire resistive pot), 1-4 Volts(hall active throttle).
•Analog Brake and Throttle Input: 0-5 Volts. Producing 0-5V signal with 3-wire pot.
•Reverse Alarm, Main Contactor Coil Driver, Meter.
•Full Power Temperature Range: 0ﹾC to 50ﹾC (controller case temperature).
•Operating Temperature Range: -30ﹾC to 90ﹾC,100ﹾC shutdown (controller case temperature).
•Motor Current Limit,1 minutes: 400A - 1800A, depending on the model.
•Motor Current Limit, continuous:200A - 900A, depending on the model.
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Kelly KDHE High Efficient Series/PM Motor Controller User’s Manual V 3.3
3.2 Connections
3.2.1 Panel of KDHE Motor Controller:
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.
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Kelly KDHE High Efficient Series/PM Motor Controller User’s Manual V 3.3
J1 Pin Definition
1- PWR: Controller power supply (output).
2- Current meter. <200mA
3- Main contactor driver. <2A
4- Alarm: To drive reverse beeper, <200mA.
5- GND: Signal return
6- Green LED: Running indication
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: Controller power supply (input)
2- GND: Signal return, or power supply ground
3- GND: Signal return
4- Motor temperature input.
5- Throttle analog input, 0-5V
6- Brake analog input, 0-5V
7- 5V: 5V supply output. <50mA
8- Micro_SW: Throttle switch input
9- Reversing switch input
10- Brake switch input
11- Reserved
12- Reserved
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Kelly KDHE High Efficient Series/PM Motor Controller User’s Manual V 3.3
13- Reserved
14- GND: Signal return
Notes:
1. All RTN and GND pins are internally connected.
2. Two PWR pins, J1-1 and J2-1, are internally connected. It’s recommended to use J1-1
to supply peripherals like alarm and contactor. Twist peripheral wires with PWR is the
preferred for EMC.
3. Kelly Ammeter positive connect to 5V power supply of controller, 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 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.
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Kelly KDHE High Efficient Series/PM Motor Controller User’s Manual V 3.3
Figure 7: KDHE Series motor controller standard wiring without Reversing Contactor
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Kelly KDHE High Efficient Series/PM Motor Controller User’s Manual V 3.3
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.
• Take the vehicle off the blocks and drive it in a clear area. It should have smooth
acceleration and good top speed.
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Kelly KDHE High Efficient Series/PM Motor Controller User’s Manual V 3.3
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.
• Discharge the capacitors in the controller by connecting a load (such as a contactor coil 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
You can configure the controller with a host computer either an through RS232.
Disconnect motor wiring from controller.
Do not connect B+, throttle and so on. The controller may display fault code in some
conditions, but it doesn't affect programming or configuration.
Use a straight through RS232 cable or Kelly USB To RS232 Converter to connect to a host
computer. Provide 10V-30V (either J2 pin1 or J1 pin1) to PWR. Wire power supply return to
any RTN pin, isolated from B-.
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Kelly KDHE High Efficient Series/PM Motor Controller User’s Manual V 3.3
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Kelly KDHE High Efficient Series/PM Motor Controller User’s Manual V 3.3
released
2. Set throttle model as "Hall Active" throttle in
GUI if you use that throttle model.
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
operation.
3,3 ¤¤¤ ¤¤¤ Hall throttle is When the throttle is repaired, a restart will clear the
open or fault.
short-circuit
3,4 ¤¤¤ ¤¤¤¤ Non-zero throttle Controller won‟t allow a direction change unless the
on direction throttle or speed is at zero. Fault clears when
change throttle is released.
4,1 ¤¤¤¤ ¤ Regen or Start-up Motor drive is disabled if an over-voltage is
over-voltage 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 Motor temperature has exceeded the configured
over-temperature 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 between two flashes is 0.5 second. The pause time between multiple flash code
groups is two seconds.
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Kelly KDHE High Efficient Series/PM Motor Controller User’s Manual V 3.3
Controller response:
ID:The controller sends data frames with ID 115, 0x73. It also can be set by configuration program.
Frame type:data frame
Length:the number of data field bytes
Data field:The controller sends one or two data frames in response.
Commands definitions
Command 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.g. 0x4B,0x42,0x4C is 'K' , 'B', 'L', 0x30 is '0' .
INFO_MODULE_NAME constant is defined as 64.
Command CCP_FLASH_READ
Length 3
data[0] 0xF2
data[1] INFO_SOFTWARE_VER
data[2] 2
Controller response
Length 2
data[0]~data[1] software version in BCD alike format, two bytes.
Description: Getting controller‟s software version, it also define as the controller‟s version, BCD
alike format storage. E.g. 0x0A,0x01 should be parsed to ASCII characters „0‟ „A‟ „0‟ „1‟ as the software
version. INFO_SOFTWARE_VER constant is defined as 83.
Command CCP_FLASH_READ
Length 3
data[0] 0xF2
data[1] CAL_TPS_DEAD_ZONE_LOW
data[2] 1
Controller response
Length 1
data[0] TPS_Dead_Zone_Low
Desccription: Getting controller‟s Throttle low-end dead zone. CAL_TPS_DEAD_ZONE_LOW
constant is defined as 4.
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Kelly KDHE High Efficient Series/PM Motor Controller User’s Manual V 3.3
Command CCP_FLASH_READ
Length 3
data[0] 0xF2
data[1] CAL_BRAKE_DEAD_ZONE_LOW
data[2] 1
Controller response
Length 1
data[0] Brake_Dead_Zone_Low
Desccription: Getting controller‟s Brake low-end dead zone. CAL_BRAKE_DEAD_ZONE_LOW
constant is defined as 5.
Command CCP_FLASH_READ
Length 3
data[0] 0xF2
data[1] CAL_TPS_DEAD_ZONE_HIGH
data[2] 1
Controller response
Length 1
data[0] TPS_Dead_Zone_High
Desccription: Getting controller‟s Throttle high-end dead zone. CAL_TPS_DEAD_ZONE_HIGH
constant is defined as 38.
Command CCP_FLASH_READ
Length 3
data[0] 0xF2
data[1] CAL_BRAKE_DEAD_ZONE_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_BATCH_READ1
Length 1
data[0] 0x1b
Controller response
Length 5
data[0] Brake A/D
data[1] TPS A/D
data[2] Operation voltage A/D
data[3] Vs A/D
data[4] B+ A/D
Description: Data batch reading.
1) For operation voltage, B+, A/D value and voltage mapping relation is:
V = Vad / 1.39. (For 144V controller).
2) Vs is defined as the 5V power supply for Hall sensor, control panel,ect. A/D value
and voltage mapping relation is:120 ~ 134 mapping to 4.75 ~ 5.25V.
3) Brake and TPS are defined as the Brake and the Throttle analog input. A/D value
and voltage mapping relation is: 0 ~ 255 mapping to 0 ~ 5V.
Command CCP_A2D_BATCH_READ2
Length 1
data[0] 0x1a
Controller response
Length 3
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data[0] Ia A/D
data[1] Ib A/D
data[2] Vb A/D
Command CCP_MONITOR1
Length 1
data[0] 0x33
Controller response
Length 6
data[0] PWM
data[1] enable motor rotation
data[2] motor temperature
data[3] Controller‟s temperature
data[4] temperature of high side FETMOS heat sink
data[5] temperature of low side FETMOS heat sink
Description: Data batch reading.
1) PWM is output duty cycle, from 0 to 100.
2) data[1] indicates enabling motor rotation or disabling. 1 - enable, 0 - disable.
3) data[2] is defined as the temperature of motor in Celsius temperature. 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 inaccurate below 30℃.
Command CCP_MONITOR2
Length 1
data[0] 0x37
Controller response
Length 3
data[0] MSB of error code
data[1] LSB of error code
data[2] present current accounts for percent of the rated current of controller
Description: Data batch reading.
1) Controller error status:(data[0] << 8) | data[1],
data[0]M 7 6 5 4 3 2 1 0 data[0]L
0x44 0x43 0x42 0x41 0x34 0x33 0x32 0x31
data[1]M 7 6 5 4 3 2 1 0 data[1]L
0x24 0x23 0x22 0x21 0x14 0x13 0x12 0x11
if(dadata[0] << 8) | data[1]=0x4008,The corresponding error code is 0x43and 0x14.
Command COM_SW_ACC
Length 2
data[0] 0x42
data[0] COM_READING
Controller response
Length 1
data[0] Current throttle switch status
Description: Getting Throttle switch status, 1 – active, 0 – inactive. COM_READING constant is
defined as 0.
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Kelly KDHE High Efficient Series/PM Motor Controller User’s Manual V 3.3
Command COM_SW_BRK
Length 2
data[0] 0x43
data[0] COM_READING
Controller response
Length 1
data[0] Current Brake switch status
Description: Getting Brake swith status, 1 – active, 0 – inactive. COM_READING 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 – active, 0 – inactive. COM_READING constant is
defined as 0.
NOTICE:
CAN bus rate should be configured to 1Mbit/s.
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Kelly KDHE High Efficient Series/PM Motor Controller User’s Manual V 3.3
Contact Us:
Kelly Controls, LLC
Home Page:
http://www.kellycontroller.com
E-mail:
[email protected]
Phone:
(01) 224 637 5092
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