Kelly KDZ72650E User manual

Kelly KDZ Series/PM Motor Controller User’s Manual V 3.5
0
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
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
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
Contact Us: .........................................................................................................19

Kelly KDZ Series/PM Motor Controller User’s Manual V 3.5
2
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
3
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
4
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
5
2.4 Naming Regulations

Kelly KDZ Series/PM Motor Controller User’s Manual V 3.5
6
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
80
12-24
30
*
KDZ24301
300
120
12-24
30
*
KDZ24401
400
160
12-24
30
*
KDZ48201
200
80
24-48
60
*
KDZ48301
300
120
24-48
60
*
KDZ48401
400
160
24-48
60
*
KDZ48551
550
220
24-48
60
*
KDZ48651E
650
260
24-48
60
*
KDZ72201
200
80
24-72
86
*
KDZ72301
300
120
24-72
86
*
KDZ72401
400
160
24-72
86
*
KDZ72551
550
220
24-72
86
*
KDZ72651E
650
260
24-72
86
*
KDZ72801E
800
320
24-72
86
*
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
7
Height: 62 millimeters
Figure 1: KDZ mounting holes’ dimensions (dimensions in millimeters)

Kelly KDZ Series/PM Motor Controller User’s Manual V 3.5
8
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
9
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