Kelly KPM48401KD User manual

KellyFullBridgePermanentMagnetMotorDcControllerUser sManual V1.4
KellyFullBridgePermanentMagnet
DcMotorControllerUser sManual
KPM48401KD
KPM48501KD
KPM72401KD
KPM72501KD
Rev.1.4
April.2017

KellyFullBridgePermanentMagnetMotorDcControllerUser sManual V1.4
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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
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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.

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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.

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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.

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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.

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Figure1: mountingholes dimensions(dimensionsinmillimeters)
3.2Connections
B+:Batterypositive(M8)
B-:Batterynegative(M8)
U=M+:armaturepositive(M8)
V=Null
W=M-:armaturenegative(M8)

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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

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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.

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3.2.2StandardWiringofKPM-KDMotorController
Figure3:KPMmotorcontrollerstandardwiring
3.2.2.1Thewiringdiagramforlowlevelbrakeswitchfunction
ThePin1=Tempcanbeusedaslowlevelbrakeswitchalso.
3.2.3CommunicationPort
A4pinconnectortoRS232converterisprovidedtocommunicatewithhostcomputerfor
calibrationandconfiguration.

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Figure4:SM-4AtoDB9(RS232)converter
(CustomermayaddanUSBtoRS232cableinaddition)
3.3InstallationCheckList
Beforeoperatingthevehicle,completethefollowingcheckoutprocedure.UseBeepError
codeasareferenceaslistedinTable1.
Caution:
•Putthevehicleuponblockstogetthedrivewheelsoffthegroundbeforebeginning
these
tests.
•Donotallowanyonetostanddirectlyinfrontoforbehindthevehicleduringthecheckout.
•MakesurethePWRswitchandthebrakeisoff
•Usewell-insulatedtools.
1.Makesurethewireisconnectedcorrectly
2.TurnthePWRswitchon.
3.Thefaultcodewillbedetectedautomaticallyatrestart.
4.Withthebrakeswitchopen,selectadirectionandoperatethethrottle.Themotorshould
spinintheselecteddirection.Verifywiringorvoltageandthefuseifitdoesnot.Themotor
shouldrunfasterwithincreasingthrottle.Ifnot,refertotheTable1code,andcorrectthe
faultasdeterminedbythefaultcode.
5.Takethevehicleofftheblocksanddriveitinacleararea.Itshouldhavesmooth
accelerationandgoodpower.

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Chapter4 Maintenance
Therearenouser-serviceablepartsinsidethecontrollers.Donotattempttoopenthe
controllerasthiswillvoidyourwarranty.However,periodic,exteriorcleaningofthecontroller
shouldbecarriedout.
Thecontrollerisahighpowereddevice.Whenworkingwithanybatterypoweredvehicle,
propersafetyprecautionsshouldbetakenthatinclude,butarenotlimitedto,propertraining,
wearingeyeprotection,avoidanceoflooseclothing,hairandjewelry.Alwaysuseinsulated
tools.
4.1Cleaning
Althoughthecontrollerrequiresvirtuallynomaintenanceafterproperlyinstallation,the
followingminormaintenanceisrecommendedincertainapplications.
•Removepowerbydisconnectingthebattery,startingwithbatterypositive.
•Dischargethecapacitorsinthecontrollerbyconnectingaload(suchasacontactorcoil,
resistororahorn)acrossthecontroller sB+andB-terminals.
•Removeanydirtorcorrosionfromthebusbararea.Thecontrollershouldbewipeddown
withamoistrag.Makesurethatthecontrollerisdrybeforereconnectingthebattery.
Makesuretheconnectionstothebusbars,iffitted,aretight.Toavoidphysicallystressing
thebusbarsusetwo,well-insulatedwrenches.
4.2Configuration
1,YoucanconfigurethecontrollerwithahostcomputerthrougheitheranRS232orUSBport.
2,DisconnectmotorwiringfromcontrollerforconfiguringexistingparametersinthePCuser
programorAndroidAPP.Ifthisoperationistoomuchextrajobforyou,pleasemakesurethe
motormustbestoppedbeforeprogramming.
3,Thecontrollermaydisplayfaultcode,butitdoesn'taffectprogrammingorconfiguration.
UseastraightthroughRS232cableorUSBconverterprovidedbyKellytoconnecttoahost
computer.Provide>+18VtoPWR（pin7）.Wirepowersupplyreturn(supplynegative)toany
RTNpinorB-.

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4,KPM-KDcontrollerrequiresaSM-4AtoDB9(RS232)converterbesidesUSBtoRS232cable
tosupportthecommunication.AndcustomersmayneedaZ-TEKUSBcableforTabletwith
AndroidOS.ItcansupportBluetoothconnectioninAndroidPhoneifcustomersuseaBluetooth
converter.
5,Thecontrollermaydisplayfaultcodeinsomeconditions,butitdoesn'taffectprogrammingor
configurationofKPM-KDcontroller.
Downloadthefreeconfigurationsoftwarefrom：
http://www.kellycontroller.com/support.php
Caution:
•MakecertainthatthemotorisdisconnectedbeforetryingtoruntheConfiguration
Software!
•Configurationsoftwarewillberegularlyupdatedandpublishedonthewebsite.Please
UpdateyourConfigurationSoftwareregularly.Youmustuninstalltheolderversion
beforeupdating.

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Table1: BeepErrorCODES
BeepErrorCode
ErrorCode Explanation Solution
Beepkeepssounding 1.Softwarestillupgrading.
2.Supplyvoltagetooloworbatterytoohigh
3.Thecontrollerisdamaged.ContactKellyabout
a
warrantyrepair.
BeepErrorCode
1,2 ¤¤¤ Overvoltageerror 1.Batteryvoltageistoohighforthecontroller.
Checkbatteryvoltsandconfiguration.
2.Regenerationover-voltage.Controllerwillhave
cutbackorstoppedregen.
3.Thisonlyaccurateto ±2%uponOvervoltage
setting.
1,3 ¤¤¤¤ Lowvoltageerror 1.Thecontrollerwillclearafter5secondsif
batteryvoltsreturnstonormal.
2.Checkbatteryvolts&rechargeifrequired.
1,4 ¤¤¤¤¤ Overtemperature
warning 1.Controllercasetemperatureisabove90 .
Currentwillbelimited.Reducecontroller
loadingorswitchOffuntilcontrollercools
down.
2.Cleanorimproveheatsinkorfan.
2,2 ¤¤ ¤¤ Internalvoltsfault 6.MeasurethatB+&PWRarecorrectwhen
measuredtoB-orRTN.
7.Theremaybeexcessiveloadonthe+5V
supplycausedbytoolowavalueofRegenor
throttlepotentiometersorincorrectwiring.
8.Controllerisdamaged.ContactKellyabouta
warrantyrepair.
2,3 ¤¤ ¤¤¤ Overtemperature Thecontrollertemperaturehasexceeded100 .
Thecontrollerwillbestoppedbutwillrestartwhen
temperaturefallsbelow80 .
2,4 ¤¤ ¤¤¤¤ Throttleerrorat
power-up Throttlesignalishigherthanthepreset ‘deadzone
atPowerOn.Faultclearswhenthrottleisreleased.
3,1 ¤¤¤ ¤ Frequentreset Maybecausedbyover-voltage,badmotor
intermittentearthingproblem,badwiring,etc.
3,2 ¤¤¤ ¤¤ Internalreset Maybecausedbysometransientfaultcondition
likeatemporaryover-current,momentarilyhighor
lowbatteryvoltage.Thiscanhappenduringnormal

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operation.
3,3 ¤¤¤ ¤¤¤ Hallthrottleis
openor
short-circuit
Whenthethrottleisrepaired,arestartwillclearthe
fault.
3,4 ¤¤¤ ¤¤¤¤ Non-zerothrottle
ondirection
change
Controllerwontallowadirectionchangeunlessthe
throttleorspeedisatzero.Faultclearswhen
throttleisreleased.
4,1 ¤¤¤¤ ¤ RegenorStart-up
over-voltage Motordriveisdisabledifanover-voltageis
detectedatstart-uporduringregen.Thevoltage
thresholddetectionlevelissetduringconfiguration.
Themaxthresholdisabout1.25timesofcontroller
ratedvoltage.I.e.youmaysetthresholdlowerthan
60Vfor48Vcontroller.
4,3 ¤¤¤¤ ¤¤¤ Motor
over-temperature Motortemperaturehasexceededtheconfigured
maximum.Thecontrollerwillshutdownuntilthe
motortemperaturecoolsdown.
CustomersmayreaderrorcodesormessageinPCsoftwareorAndroidApp.
ContactUs:
KellyControls
HomePage:
http://www.KellyController.com
Downloadusermanual,instructionsanduserprogram:
www.kellycontroller.com/support.php
E-mail:
[e-mail]
Phone:
(01)2246375092