Kelly High voltage khda series User manual

Kelly

Kelly KDHA

KDHA

KDHA High

High

High Voltage

Voltage

Voltage Series/PM

Series/PM

Series/PM Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Manual V

V

V 3.1

3.1

Kelly

Kelly KDHA

KDHA

KDHA High

High

High Voltage

Voltage

Voltage Series/PM

Series/PM

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Rev. 3.1

Dec /200 8

KDH07600A

KDH07601

KDH07601 A

A

KDH07800A

KDH07801

KDH07801 A

A

KDH09400

KDH09400 A

A

KDH09401

KDH09401 A

A

KDH09

KDH09 5

5

5 00

00

00 A

A

KDH09

KDH09 5

5

5 01

01

01 A

A

KDH12

KDH12 4

4

4 00

00

00 A

A

KDH12

KDH12 4

4

4 0

0

0 1A

1A

KDH12

KDH12 5

5

5 00

00

00 A

A

KDH12

KDH12 5

5

5 01

01

01 A

A

KDH14

KDH14 2

2

2 00

00

00 A

A

KDH14

KDH14 2

2

2 0

0

0 1A

1A

KDH14

KDH14 4

4

4 00

00

00 A

A

KDH14

KDH14 4

4

4 01

01

01 A

A

Kelly

Kelly KDHA

KDHA

KDHA High

High

High Voltage

Voltage

Voltage Series/PM

Series/PM

Series/PM Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Manual V

V

V 3.1

3.1

Page 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 ...................................................................................................... 3

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

Chapter 3 Wiring and Installation ............................................................................5

3.1 Mounting the Controller .............................................................................. 5

3.2 Connections ................................................................................................ 7

3.3 Installation Checkout ................................................................................ 13

Chapter 4 Maintenance .........................................................................................14

4.1 Cleaning ....................................................................................................14

4.2 Configuration .............................................................................................14

Table 1: LED CODES ............................................................................................15

Contact Us: ........................................................................................................... 17

Kelly

Kelly KDHA

KDHA

KDHA High

High

High Voltage

Voltage

Voltage Series/PM

Series/PM

Series/PM Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Manual V

V

V 3.1

3.1

Page 2

Chapter

Chapter 1

1

1 Introduction

Introduction

1.1

1.1 Overview

Overview

The manual introduce s Kelly HIGH VOLTAGE motor controller features, installation and

maintenance. R ead the manual carefully and thoroughly before use the controller. Should you

have any questions, please contact the support center of Kelly Controls, LLC.

Kelly

’

s programmable motor controllers provide efficient, smooth and quite control s for

electrical vehicles like golf cart, go-cart, electric motorcycle, fork lift, hybrid vehicle , as well as

electric boat and industry motor speed control. It uses high power MOSFET, fast PWM to achieve

efficiency 9 9 % in most cases. Powerful microprocessor brings in comprehensive and precise

control to the controllers. It also allow s users to set parameters, conduct tests, and obtain

diagnostic information quickly and easily.

Kelly

Kelly KDHA

KDHA

KDHA High

High

High Voltage

Voltage

Voltage Series/PM

Series/PM

Series/PM Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Manual V

V

V 3.1

3.1

Page 3

Chapter

Chapter 2

2

2 Main

Main

Main Features

Features

Features and

and

and Specifications

Specifications

2.1

2.1 General

General

General functions

functions

(1)

Extended fault detection and protection. LED flashing for fault code.

(2)

Monitoring battery voltage

.

It will s top driving if battery voltage is too high

.

It will cut back then

stop driving if voltage is going too low.

(3)

Built-in current loop and over current protection.

(4)

Controller temperature measurement and protection

(5)

Current cutback at low temperature and high temperature to protect battery and controller.

The current will ramp down quickly if controller temperature is higher than 90C, and shutdown

at 100C. Low temperature current ramping down usually starts at 0C.

(6)

The controller keeps monitoring voltage during regen. It will cut back current then cut off regen

if voltage is going too high.

(7)

Configurable to limit max reverse speed to half of max forward speed

.

(8)

Configurable and programmable with RS-232. Software upgradeable. Windows GUI provided.

(9)

Provide 5V sensor supply

(10)

3 switch inputs. Close to ground to activate. Default to throttle switch, brake switch and

reverse switch.

(11)

3 analog inputs, 0-5V. Default to throttle input, brake input and motor temperature input

(12)

Reverse alarm output. Recirculation diodes provided.

(13)

Main c ontactor driver. Cut off the power if any fault detected .

(14)

Configurable max reverse power to half.

(15)

Motor over temperature detection and protection, with recommended thermistor .

(16)

Optional CAN bus.

(17)

Optional supply voltage 8V- 3

0V.

Caution! Regeneration has braking effect, but can't replace mechanical brake. Mechanical brake

is required to stop your vehicle. Regen isn

’

t a safety feature! Controller may stop regen to protect

itself (not you!).

2.2

2.2 Features

Features

• Intelligence with powerful microprocessor.

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

• Current limit and torque control.

• Low EMC.

• LED fault code help s user debugging.

• Battery protection: current cut back, shutdown and warning at low battery.

• Thermal enhanced rugged aluminum housing. Rugged connectors.

• Thermal protection: Current cut back on low temperature and high temperature to protect battery

and controller.

• High pedal protection: Disable operation if power up with non-zero throttle.

Kelly

Kelly KDHA

KDHA

KDHA High

High

High Voltage

Voltage

Voltage Series/PM

Series/PM

Series/PM Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Manual V

V

V 3.1

3.1

Page 4

• Brake switch is used to start regen.

• 0-5V brake signal is used to command regen current.

2.3

2.3 Specifications

Specifications

•Frequency of Operation: 16.6kHz.

•Standby Battery Current: <3 mA.

•Supply Voltage, PWR, 8 to 30

V.

•Supply Current, 200mA @ 12V, or 2.5W

•Operating Voltage, B+, 18V to 136V

•Analog Brake and Throttle Input: 0-5 Volts.

.

Can use 3- wire pot to produce 0-5V signal.

•Reverse Alarm, Main Contactor Coil Driver, Meter: < 1.5 A.

•Full Power Temperature Range: 0C to 40C (controller case temperature).

•Operating Temperature Range: -30C to 90C, 100C shutdown (controller case temperature).

•Motor Current Limit, 1 0 seconds boost: 200A,400A,500A,600A,800A , depending on model.

•Motor Current Limit, 1 minutes: 300A,350A,400A,60 0A ,800A , depending on model.

•Motor Current Limit, continuous: 100A,160A,200A,24 0A ,320A , depending on model.

Kelly High Voltage DC Motor Controller

Model

1 0

seconds

boost

current

1 minutes

current

continuous

current

Nominal

Voltage

Range

Max operating

voltage

Regen

KDH07600A

600A

240A

24V-72V

18V- 90 V

KDH07601A

600A

240A

24V-72V

18V- 90 V

*

KDH07800A

800A

320A

24V-72V

18V- 90 V

KDH07801A

800A

320A

24V-72V

18V- 90 V

*

KDH 09400A

400A

300A

160A

24V-96V

18V-1 20 V

KDH 09401A

400A

300A

160A

24V-96V

18V-1 20 V

*

KDH 09500A

500A

400A

200A

24V-96V

18V-1 20 V

KDH 09501A

500A

400A

200A

24V-96V

18V-1 20 V

*

KDH12 4 00 A

400A

300 A

160A

24V-120V

18V-136V

KDH12401 A

400A

300 A

160A

24V-120V

18V-136V

*

KDH12 5 00 A

500A

400 A

200A

24V-120V

18V-136V

KDH12 5 01 A

500A

400 A

200A

24V-120V

18V-136V

*

KDH14 2 0 0A

200A

150 A

100A

24V-144V

18V-168V

KDH14 2 0 1A

200A

150 A

100A

24V-144V

18V-180V

*

KDH14 4 00 A

400A

350 A

160A

24V-144V

18V-168V

KDH14 4 0 1A

400A

350 A

160A

24V-144V

18V-180V

*

For supply voltage, all KDHA controller s are 8V-3 0

V

.

Kelly

Kelly KDHA

KDHA

KDHA High

High

High Voltage

Voltage

Voltage Series/PM

Series/PM

Series/PM Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Manual V

V

V 3.1

3.1

Page 5

Chapter

Chapter 3

3

3 Wiring

Wiring

Wiring and

and

and Installation

Installation

3.1

3.1 Mounting

Mounting

Mounting the

the

the Controller

Controller

The controller can be oriented in any position as clean and dry as possible , or shield 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 gel or other thermal conductive material to contact

surface will enhance thermal performance.

Sufficient heat sink and air flow is required for high power application.

The case outline and mounting hole dimensions are shown in Figure 1.

Caution:

•RUNAWAYS

RUNAWAYS

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

HIGH

HIGH CURRENT

CURRENT

CURRENT ARCS

ARCS

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 .

Kelly

Kelly KDHA

KDHA

KDHA High

High

High Voltage

Voltage

Voltage Series/PM

Series/PM

Series/PM Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Manual V

V

V 3.1

3.1

Page 6

Tall: 62 millimeters

Figure

Figure 1:

1:

1: mounting hole dimensions ( dimensions in millimeter s)

Kelly

Kelly KDHA

KDHA

KDHA High

High

High Voltage

Voltage

Voltage Series/PM

Series/PM

Series/PM Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Manual V

V

V 3.1

3.1

Page 7

3.2

3.2 Connections

Connections

3.2.1

3.2.1 Front

Front

Front Panel

Panel

Panel of

of

of KDH

KDH

KDH Motor

Motor

Motor Controller:

Controller:

Five metal bars and two plugs (J1, J2) are provided for connections to the battery, motor and

control signals in the front of the controller shown as Figure 2 .

Figure

Figure 2:

2:

2: Front panel of KDHA motor controller picture

B+:

B+: Battery

Battery

Battery positive

positive

B-:

B-: Battery

Battery

Battery negative

negative

M:

M: Armature

Armature

Armature Output

Output

Figure

Figure 3:

3:

3: The connecting diagram of J1

J1

J1 and J2

J2

J1

J1 Pin

Pin Definition

Definition

1-

1- PWR

PWR

PWR :

:

: Control

Control

Control ler

ler

ler power

power

power supply

supply

supply (output).

(output).

(output). The

The

The pin

pin is

is

is Red

Red

LED

LED for

for

for S/N

S/N

S/N less

less

less :08XXXXXX.

:08XXXXXX.

2-

2- Current

Current

Current meter.

meter.

meter. <200mA

<200mA

3-

3- Main

Main

Main contactor

contactor

contactor driver.

driver.

driver. <

<

< 1.5

1.5

1.5 A

A

4-

4- Alarm:

Alarm:

Alarm: To

To

To drive

drive

drive reverse

reverse

reverse beeper

beeper

beeper ,

,

, <200mA

<200mA

<200mA .

.

5-

5- GND:

GND:

GND: Signal

Signal

Signal return

return

6-

6- Green

Green

Green LED:

LED:

LED: Running

Running

Running indication

indication

7-

7- GND:

GND:

GND: Signal

Signal

Signal return

return

8-

8- RS232

RS232

RS232 receiv

receiv

receiv er

er

9-

9- RS232

RS232

RS232 transmitt

transmitt

transmitt er

er

10-

10- CAN

CAN

CAN bus

bus

bus high

high

high .

.

. Optional

Optional

Kelly

Kelly KDHA

KDHA

KDHA High

High

High Voltage

Voltage

Voltage Series/PM

Series/PM

Series/PM Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Manual V

V

V 3.1

3.1

Page 8

11-

11- CAN

CAN

CAN bus

bus

bus low

low

low .

.

. Optional

Optional

12-

12- Reserved

Reserved

13-

13- GND:

GND:

GND: Signal

Signal

Signal r

r

r eturn,

eturn,

eturn, or

or

or power

power

power supply

supply

supply ground

ground

14-

14- Red

Red

Red LED:

LED:

LED: F

F

F ault

ault

ault code

code

code .The

.The

.The pin

pin is

is

is PWR

PWR

PWR for

for

for S/N

S/N

S/N less

less

less :08XXXXXX.

:08XXXXXX.

J2

J2 Pin

Pin Definition

Definition

1-

1- PWR

PWR

PWR :

:

: Control

Control

Control ler

ler

ler power

power

power supply

supply

supply (input)

(input)

2-

2- GND:

GND:

GND: Signal

Signal

Signal r

r

r eturn,

eturn,

eturn, or

or

or power

power

power supply

supply

supply ground

ground

3-

3- GND:

GND:

GND: Signal

Signal

Signal r

r

r eturn

eturn

4-

4- Motor

Motor

Motor temperature

temperature

temperature input.

input.

5-

5- Throttle

Throttle

Throttle analog

analog

analog input,

input,

input, 0-5V

0-5V

6-

6- B

B

B rake

rake

rake analog

analog

analog input

input

input ,

,

, 0-5V

0-5V

7-

7- 5V:

5V:

5V: 5V

5V

5V supply

supply

supply output.

output.

output. <40mA

<40mA

8-

8- Throttle

Throttle

Throttle switch

switch

switch input

input

9-

9- R

R

R everse

everse

everse switch

switch

switch input

input

10-

10- Brake

Brake

Brake switch

switch

switch input

input

11-

11- Reserved

Reserved

12-

12- Reserved

Reserved

13-

13- Reserved

Reserved

14-

14- GND:

GND:

GND: Signal

Signal

Signal r

r

r eturn

eturn

Notes:

1.

1. All

All

All GND

GND

GND pins

pins

pins are

are

are internally

internally

internally connected.

connected.

2.

2. Two

Two

Two PWR

PWR

PWR pins,

pins,

pins, J1-14

J1-14

J1-14 and

and

and J2-1,

J2-1,

J2-1, are

are

are internally

internally

internally connected.

connected.

connected. It

It

It ’

’

’ s

s

s recommended

recommended

recommended to

to

to use

use

use J1-

J1-

14

14 to

to

to supply

supply

supply peripherals

peripherals

peripherals like

like

like alarm

alarm

alarm and

and

and meters.

meters.

meters. Twist

Twist

Twist peripheral

peripheral

peripheral wires

wires

wires with

with

with PWR

PWR

PWR is

is

is the

the

preferred

preferred for

for

for EMC.

EMC.

EMC. Recirculation

Recirculation

Recirculation diodes

diodes

diodes are

are

are provided

provided

provided in

in

in the

the

the controller

controller

controller to

to

to PWR

PWR

PWR for

for

for ala

ala

ala rm

rm

and

and meter

meter

meter drivers.

drivers.

3.

3. Switch

Switch

Switch to

to

to ground

ground

ground is

is

is active.

active.

active. Open

Open

Open switch

switch

switch is

is

is inactive

inactive

3.2.

3.2. 2

2

2 Standard

Standard

Standard Wiring

Wiring

Wiring of

of

of KDHA

KDHA

KDHA Motor

Motor

Motor Controller

Controller

Caution:

Caution: Make

Make

Make sure

sure

sure all

all

all connections

connections

connections are

are

are correct

correct

correct before

before

before apply

apply

apply power.

power.

power. O

O

O therwise

therwise

therwise it

it

it may

may

may damage

damage

the

the controller!

controller!

controller! Please

Please

Please securely

securely

securely wire

wire

wire B-

B-

B- before

before

before applying

applying

applying power.

power.

power. It's

It's

It's preferred

preferred

preferred to

to

to place

place

contactor

contactor or

or

or breaker

breaker

breaker on

on

on B+.

B+.

B+. Don't

Don't

Don't connect

connect

connect GND

GND

GND to

to

to B-.Please

B-.Please

B-.Please place

place

place precharge

precharge

precharge resistor

resistor

resistor on

on

on any

any

breaker!

breaker! It

It

It can

can

can cause

cause

cause damage

damage

damage without

without

without it!!!

it!!!

Kelly

Kelly KDHA

KDHA

KDHA High

High

High Voltage

Voltage

Voltage Series/PM

Series/PM

Series/PM Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Manual V

V

V 3.1

3.1

Page 9

Figure

Figure 4

4

4 :

:

: KDH

KDH

KDH A

A

A Series

Series

Series motor

motor

motor controller

controller

controller standard

standard

standard wiring

wiring

Kelly

Kelly KDHA

KDHA

KDHA High

High

High Voltage

Voltage

Voltage Series/PM

Series/PM

Series/PM Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Manual V

V

V 3.1

3.1

Page 10

Figure

Figure 5:KDHA

5:KDHA

5:KDHA Series

Series

Series motor

motor

motor controller

controller

controller standard

standard

standard wiring

wiring

wiring without

without

without Reversing

Reversing

Reversing Contactor

Contactor

Kelly

Kelly KDHA

KDHA

KDHA High

High

High Voltage

Voltage

Voltage Series/PM

Series/PM

Series/PM Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Manual V

V

V 3.1

3.1

Page

11

Figure

Figure 6

6

6 :

:

: KDH

KDH

KDH A

A

A PM

PM

PM motor

motor

motor controller

controller

controller standard

standard

standard wiring

wiring

Kelly

Kelly KDHA

KDHA

KDHA High

High

High Voltage

Voltage

Voltage Series/PM

Series/PM

Series/PM Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Manual V

V

V 3.1

3.1

Page 12

Figure

Figure 7:

7:

7: KDH

KDH

KDH A

A

A PM

PM

PM motor

motor

motor controller

controller

controller standard

standard

standard wiring

wiring

wiring without

without

without Reversing

Reversing

Reversing Contactor

Contactor

Kelly

Kelly KDHA

KDHA

KDHA High

High

High Voltage

Voltage

Voltage Series/PM

Series/PM

Series/PM Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Manual V

V

V 3.1

3.1

Page 13

3.2.

3.2. 3

3

3 Communication

Communication

Communication Port

Port

A

RS232 port of controller is provided to communicate with host computer for calibration and configuration.

Figure

Figure 8:

8:

8: standard RS232 interface

3.3

3.3 Installation

Installation

Installation Checklist

Checklist

Before operating the vehicle, complete the following checkout procedure. Use LED code as a

reference. The LED codes are listed in

T

able 1 .

•Make sure the wire is connected correctly

•Turn the PWR switch on. T he LED should blink, then keeps on when the controller operate s

normally. If this does not happen, check continuity of the PWR and controller ground.

•T he fault code will be detected automatically at restart .

•With the brake switch open, select a direction and operate the throttle. The motor should spin

in the selected direction. Please verify wiring and voltage if it doesn ’ t. Also check fuse. The

motor should run faster with increasing throttle. If not, refer to Table 1 LED code, and correct

the fault according to the code.

•Take the vehicle off the blocks and drive it in a clear area. It should have smooth acceleration

and good top speed.

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 .

Kelly

Kelly KDHA

KDHA

KDHA High

High

High Voltage

Voltage

Voltage Series/PM

Series/PM

Series/PM Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Manual V

V

V 3.1

3.1

Page 14

Chapter

Chapter 4

4

4 Maintenance

Maintenance

There are no user-serviceable parts inside the controllers. Do not attempt to open the

controller. Or you will damage it. However, clearing the controller exterior periodically should be

necessary.

The controller is inherently a high power device. When working with any battery powered

vehicle, proper safety precautions should be taken. These include, but are not limited to: proper

training, wearing eye protection, avoiding loose clothing and jewelry , and using insulated

wrenches.

4.1

4.1 Cleaning

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 with a

moist rag. Be sure it is dry before reconnecting the battery.

•

•Make sure the connections to the bus bars are tight. Use two wrenches for this task in order

to avoid stressing the bus bars; the wrenches should be well insulated.

4.2

4.2 Configuration

Configuration

You can configure the controller with a host computer through RS232.

•Use a standard RS232 cable connecting the 9pin connector on face penal to a host computer.

The cable should be straight.

•Provide 8V to 30 V supply to PWR (either J2 pin1 or J1 pin14). Wire power supply ground to

any GND pin.

•Do not connect B+, throttle and so on. The controller may display fault code, but it doesn't

affect programming or configuration .

Kelly

Kelly KDHA

KDHA

KDHA High

High

High Voltage

Voltage

Voltage Series/PM

Series/PM

Series/PM Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Manual V

V

V 3.1

3.1

Page 15

Table

Table 1:

1:

1: LED

LED

LED CODES

CODES

LED Code

Explanation

S olution

Green

O ff

No power or no t

operating

1. Check if all wires are correct .

2. Check fuse and power supply.

Green

On

Normal operation

That

’

s great!

You

got solution!

1,2

¤ ¤¤

O ver voltage error

1.

Battery voltage is higher than max operating

voltage of the controller. P lease check the

battery voltage and configuration.

2.

Over voltage at regeneration. Controller will cut

back or s top regeneration .

1,3

¤ ¤¤¤

Low voltage error

1.

The controller will attempt to clear the fault

code automatically after 5 second if battery

return to normal.

2.

Check the battery voltage .

3.

C harge battery if necessary.

1,4

¤ ¤¤¤¤

Over t emperature

warning

1.

The controller temperature is over 90 º C. The

controller will cut back current in the case.

S top or reduce output to ensure the

temperature fall.

2.

Improve heat sink or airflow

2,1

¤¤ ¤

Throttle sensor

fault

1.

Check if the connecting is corre c t .

2.

C heck if the voltage is in 0- 5V .

2,2

¤¤ ¤¤

I nternal voltage

fault

1.

Check if the B+ and PWR voltage are correct ,

refer to B- or RTN. Could be PWR voltage low .

2.

Please check load on 5V supply. Could be high

load on

5V.

Incorrect pot wiring can load it

heavily 。

1.

The controller is damaged . Please contact

Kelly for warrantee.

2,3

¤¤ ¤¤¤

O ver temperature

1.

The controller temperature is over 100 º C .

Controller s top s driving in order to protect itself.

2.

Stop driving and wait for temperature fall. T he

controller will restart if temperature drops below

80 º C.

2,4

¤¤ ¤¤¤¤

Throttle error at

power up

1.

The throttle signal is higher than configured

dead zone at power-on

2.

The fault will disappear if restart or release

throttle.

3,1

¤¤¤ ¤

Frequent reset

1.

The controller will stop driving after detect too

many resets.

2.

Mostly because of B- or return wiring. Use

Kelly

Kelly KDHA

KDHA

KDHA High

High

High Voltage

Voltage

Voltage Series/PM

Series/PM

Series/PM Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Manual V

V

V 3.1

3.1

Page 16

heavier and clean return wires. For dual

controllers, bond B- of both controllers together

with heavy cable or copper strip.

3.

Could be over current protection. May set max

current lower.

4.

Restart will clear the error.

5. Please contact Kelly if it happens repeatedly

3,2

¤¤¤ ¤¤

Internal r eset

Reset caused by over current, h igh battery voltage

or low supply voltage . I t is normal if occurs

occasionally.

3,4

¤¤¤ ¤¤¤¤

Throttle isn ’ t zero

when try to

change direction

The controller won ’ t change drive direction if

throttle isn ’ t zero. Also it won ’ t change direction at

high speed. The controller will wait throttle and

speed close

to

zero before change direction.

4,1

¤¤¤¤ ¤

Over voltage at

startup or

regeneration

The controller won ’ t drive motor if detect

overvoltage at power up. It will cut back regen

current or stop regen if detect overvoltage during

regen.

You

may set overvoltage threshold with GUI .

The max threshold is about 1.25 times of

controller rated volt age. I.e. you may set threshold

lower than 60V for 48V controller.

T he LED flashes once at power on, then keeps on for normal operation . “ 1, 2 ”

means it flashed once , then flashes twice after 1 second. The time between two flashes

is 0.5 second. The pause time between one error code and another error code is 2

second.

Kelly

Kelly KDHA

KDHA

KDHA High

High

High Voltage

Voltage

Voltage Series/PM

Series/PM

Series/PM Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Manual V

V

V 3.1

3.1

Page 17

Contact

Contact Us:

Us:

Kelly

Kelly Controls,

Controls,

Controls, LLC

LLC

Home

Home Page:

Page:

http://www.kellycontroller.com

E-mail:

support@kellycontroller.com

Phone:

( 0 1) 224 637 5092

Kelly HIGH VOLTAGE KHDA Series User manual

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