KEYA PM24201, PM36201, PM36101, PM24301, PM48201 User Manual

Kelly

Kelly Full

Full

Full Bridge

Bridge

Bridge Permanent

Permanent

Permanent Magnet

Magnet

Magnet Motor

Motor

Motor Dc

Dc

Dc Controller

Controller

Controller User

User

User ’

’

’ s

s

s Manual

Manual

Manual V

V

V 3.

3.

3. 2

2

Kelly

Kelly Full

Full

Full Bridge

Bridge

Bridge Permanent

Permanent

Permanent Magnet

Magnet

Dc

Dc Motor

Motor

Motor Controller

Controller

Controller User

User

’

s

s Manual

Manual

Rev. 3. 2

Oct. 200 9

PM24101

PM24201

PM24

PM24 3

3

3 01

01

PM

PM 36

36

36 101

101

PM

PM 36

36

36 2

2

2 01

01

PM48101

PM48

PM48 2

2

2 01

01

PM48

PM48 3

3

3 01

01

PM48

PM48 4

4

4 01

01

01 B

B

PM48

PM48 5

5

5 01

01

01 B

B

PM72101

PM72

PM72 2

2

2 01

01

PM72

PM72 3

3

3 01

01

PM72401

PM72401 B

B

PM72501

PM72501 B

B

PM72

PM72 6

6

6 01

01

01 B

B

PM

PM 12151H

12151H

PM

PM 12251H

12251H

PM

PM 12271H

12271H

PM

PM 12401H

12401H

Kelly

Kelly Full

Full

Full Bridge

Bridge

Bridge Permanent

Permanent

Permanent Magnet

Magnet

Magnet Motor

Motor

Motor Dc

Dc

Dc Controller

Controller

Controller User

User

User ’

’

’ s

s

s Manual

Manual

Manual V

V

V 3.

3.

3. 2

2

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

Chapter 3 Wiring and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.1 Mounting the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.3 Installation Check list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2

Chapter 4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3

4.1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3

4.2 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3

Table 1: LED CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4

Contact Us: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6

Kelly

Kelly Full

Full

Full Bridge

Bridge

Bridge Permanent

Permanent

Permanent Magnet

Magnet

Magnet Motor

Motor

Motor Dc

Dc

Dc Controller

Controller

Controller User

User

User ’

’

’ s

s

s Manual

Manual

Manual V

V

V 3.

3.

3. 2

2

Page 2

Chapter1

Chapter1 Introduction

Introduction

1.1

1.1 Overview

Overview

The manual introduce s Kelly PM motor controller s’features, installation and maintenance. R ead the manual carefully and thoroughly before us ing 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 quite control s for electrical vehicles like golf cart, go-cart, electric motorcycle, scooter, fork lift, hybrid vehicle , as well as electric boat and industry motor speed control. It uses high power MOSFET , PWM to achieve efficiency 99% 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’s PM motor controller is full bridge or 4 quadrant controller. It provides fast and reliable electronic direction control. There i s no arc, spark, or life limit on motor direction changes.

Kelly

Kelly Full

Full

Full Bridge

Bridge

Bridge Permanent

Permanent

Permanent Magnet

Magnet

Magnet Motor

Motor

Motor Dc

Dc

Dc Controller

Controller

Controller User

User

User ’

’

’ s

s

s Manual

Manual

Manual V

V

V 3.

3.

3. 2

2

Page 3

Chapter2

Chapter2 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 code i ndicate s fault sources.

(2)

Monitoring battery voltage.Stop driving if battery voltage is too high or too low.

(3)

Built-in current loop and over current protection.

(4)

Controller’s temperature measurement and protection

(5)

Cut ting back c urrent at low temperature and high temperature to protect battery and controller. The current will ramp down quickly if controller temperature is higher than 90 ℃ , and shut down at 100 ℃

.

Low temperature current ramping down usually starts at 0 ℃ .

(6)

Two RS232 ports. Both can be used for configuration .

(7)

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

(8)

Provide 5V sensor supply

. (9) 3 switch inputs : Default to throttle switch, brake switch and reverse switch. Clos ing to ground is to activate . (10) 3 analog inputs, 0-5V : Default to throttle input, brake input and motor temperature input . (11)

Reverse alarm output. Recirculation diodes provided.

(12) Main c ontactor driver. Cut off the power if any fault is detected

. (13) Current meter to display both drive and regen current. Save shunt. (14) Configurable b oost switch

.

Output can arrive at the maximum current if the switch is enable d and turned on. (15) Configurable t urbo switch

.

Limit max power to half if the switch is enable d and turned on. (16) Configurable max reverse power to half. (17) Enhanced regen brake function. Novel ABS technique provides powerful and smooth regen. (18) Configurable 12V brake signal input, in lieu of motor temperature sensor. (19) Optional joystick throttle. Single 0-5V signal for both forward ing and reversing. (20) Thermal overload detection and protection to safeguard the motor from over temperature, with recommended Silicon temperature sensors KTY83-122 . (21) Using battery-powered. (22) Optional CAN bus. (23) Optional supply voltage 8V- 3

0V.

Kelly

Kelly Full

Full

Full Bridge

Bridge

Bridge Permanent

Permanent

Permanent Magnet

Magnet

Magnet Motor

Motor

Motor Dc

Dc

Dc Controller

Controller

Controller User

User

User ’

’

’ s

s

s Manual

Manual

Manual V

V

V 3.

3.

3. 2

2

Page 4

2.2

2.2 Features

Features

• Intelligence with powerful microprocessor.

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

• Current limit and torque control. Configurable torque mode and speed mode.

• Low EMC.

• LED fault code help s user debugging.

• Battery protection: Current cutback, shutdown and warning at low battery.

• R ugged aluminum housing for maximum heat dissipation.

• Thermal protection: Current cut s back at low temperature and high temperature to protect

battery and controller.

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

• Brake switch is used to start regen.

• Able to control and change the motor’s running direction directly.

• Full Programmable with RS-232. Software upgradeable. Free Windows GUI software.

• Three modes of regen: brake switch regen, release throttle regen, 0-5V signal regen.

• No adjustment.

2.3

2.3 Specifications

Specifications

• Frequency of Operation: 16.6kHz.

• Standby Battery Current: < 1 mA.

• 5V Sensor Supply Current: 40mA.

• Supply Voltage, PWR, 18V to B+ ( 8 V to 30V for Controllers r ated equal 24 V )

• Supply Current, PWR,150mA.

• Standard Throttle Input: 0-5 Volts. P roduc ing 0-5V signal with 3- wire pot .

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

• Reverse Alarm, Main C ontactor Coil Driver, Meter.

• Full Power T emperature Range: 0 ℃ to 50 ℃ (controller case temperature).

• Operating Temperature Range: -30 ℃ to 90 ℃ , 100 ℃ s hutdown (controller case temperature).

• Motor Current Limit , 1 minutes: 100A - 6 0 0A.depending on model.

• Motor Current Limit , continuous: 40 A-2 4 0A , depending on model.

• Max Battery Current : Configurable .

Kelly

Kelly Full

Full

Full Bridge

Bridge

Bridge Permanent

Permanent

Permanent Magnet

Magnet

Magnet Motor

Motor

Motor Dc

Dc

Dc Controller

Controller

Controller User

User

User ’

’

’ s

s

s Manual

Manual

Manual V

V

V 3.

3.

3. 2

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Page 5

Kelly Full Bridge Permanent Magnet DC Motor Controller

Model

1 minute

C urrent

C ontinuous

C urrent

Rated

Voltage

Range

Regen

PM24101

100A

40A

24V

12 V- 24 V

Yes

PM24201

200A

80A

24V

12 V- 24 V

Yes

PM24301

300A

120A

24V

12 V- 24 V

Yes

PM 36 101

100A

40A

36 V

24 V- 36 V

Yes

PM 36 201

200A

80A

36 V

24 V- 36 V

Yes

PM48101

100A

40A

48V

24 V- 48 V

Yes

PM48201

200A

80A

48V

24 V- 48 V

Yes

PM48 3 01

3 00A

12 0A

48V

24 V- 48 V

Yes

PM48401 B

400A

160A

48V

24 V- 48 V

Yes

PM48501 B

500A

200A

48V

24 V- 48 V

Yes

PM72101

100A

40A

72V

24 V- 72 V

Yes

PM72201

200A

80A

72V

24 V- 72 V

Yes

PM72 3 01

3 00A

12 0A

72V

24 V- 72 V

Yes

PM72401 B

400A

160A

72V

24 V- 72 V

Yes

PM72501 B

500A

200A

72V

24 V- 72 V

Yes

PM72 6 01 B

6 00A

2 4 0A

72V

24 V- 72 V

Yes

PM

12 151H15 0 A

6 0A

120V

24 V- 120 V

Yes

PM 12251H

2 5 0 A

1 0 0A

120V

24 V- 120 V

Yes

PM 12271H

270 A110A

120V

24 V- 120 V

Yes

PM 12 40 1H

40 0 A

1 6 0A

120V

24 V- 120 V

Yes

Female plugs of J1&J2 will be shipped for free.

Kelly

Kelly Full

Full

Full Bridge

Bridge

Bridge Permanent

Permanent

Permanent Magnet

Magnet

Magnet Motor

Motor

Motor Dc

Dc

Dc Controller

Controller

Controller User

User

User ’

’

’ s

s

s Manual

Manual

Manual V

V

V 3.

3.

3. 2

2

Page 6

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 s’dimensions are shown in Figure 1.

Caution:

• RUNAWAYS

RUNAWA YS

RUNAWA YS — 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 circuit .

Kelly

Kelly Full

Full

Full Bridge

Bridge

Bridge Permanent

Permanent

Permanent Magnet

Magnet

Magnet Motor

Motor

Motor Dc

Dc

Dc Controller

Controller

Controller User

User

User ’

’

’ s

s

s Manual

Manual

Manual V

V

V 3.

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Page 7

Height : 62 millimeters

Figure

Figure 1:

1:

1: mounting hole s ’ dimensions ( dimensions in millimete rs )

Height : 62 millimeters

Figure

Figure 2

2

2 :

:

: PM-H/B mounting hole s ’ dimensions ( dimensions in millimeter s)

Kelly

Kelly Full

Full

Full Bridge

Bridge

Bridge Permanent

Permanent

Permanent Magnet

Magnet

Magnet Motor

Motor

Motor Dc

Dc

Dc Controller

Controller

Controller User

User

User ’

’

’ s

s

s Manual

Manual

Manual V

V

V 3.

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3. 2

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Page 8

3.2

3.2 Connections

Connections

3.2.1

3.2.1 Front

Front

Front Panel

Panel

Panel of

of

of PM

PM

PM Motor

Motor

Motor Controller:

Controller:

F our metal bars and two plugs (J1, J2) are provided for connecti ng to the battery, motor

and control signals in the front of the controller shown as Figure 3 .

Figure

Figure 3

3

3 :

:

: Front panel of PM motor controller

B+:

B+: Ba

Ba

Ba ttery

ttery

ttery positive

positive

B-:

B-: Battery

Battery

Battery negative

negative

M

M +

+

+ :

:

: armature

armature

armature positive

positive

M

M -

-

- :

:

: armature

armature

armature negative

negative

Figure

Figure 4

4

4 :

:

: The

The

The connecting

connecting

connecting diagram

diagram

diagram of

of

of J1

J1

J1 and

and

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

Red

Red LED

LED

LED for

for

for S/N

S/N

S/N less:

less:

less: 08XXXXXX

08XXXXXX

08XXXXXX .

.

2-

2- Current

Current

Current meter

meter

meter <200mA.

<200mA.

3-

3- Main

Main

Main contactor

contactor

contactor driver

driver

driver <

<

< 4

4

4 00mA.

00mA.

4-

4- Alarm:

Alarm:

Alarm: To

To

To drive

drive

drive reverse

reverse

reverse beeper.

beeper.

beeper. <200mA

<200mA

5-

5- RTN:

RTN:

RTN: Signal

Signal

Signal return

return

6-

6- Green

Green

Green LED:

LED:

LED: Running

Running

Running indication

indication

7-

7- RTN:

RTN:

RTN: 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

11-

11- CAN

CAN

CAN bus

bus

bus low

low

12-

12- Reserved

Reserved

13-

13- RTN:

RTN:

RTN: Signal

Signal

Signal r

r

r eturn,

eturn,

eturn, or

or

or power

power

power supply

supply

supply return

return

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

08XXXXXX .

.

Kelly

Kelly Full

Full

Full Bridge

Bridge

Bridge Permanent

Permanent

Permanent Magnet

Magnet

Magnet Motor

Motor

Motor Dc

Dc

Dc Controller

Controller

Controller User

User

User ’

’

’ s

s

s Manual

Manual

Manual V

V

V 3.

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Page 9

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- RTN:

RTN:

RTN: Signal

Signal

Signal r

r

r eturn,

eturn,

eturn, or

or

or power

power

power supply

supply

supply ground

ground

3-

3- RTN:

RTN:

RTN: 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 supply

supply

supply output

output

output .<40mA

.<40mA

8-

8- Micro_SW:

Micro_SW:

Micro_SW: 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- RTN:

RTN:

RTN: Signal

Signal

Signal r

r

r eturn

eturn

Notes:

1.

1. All

All

All RTN

RTN

RTN pins

pins

pins are

are

are internally

internally

internally connected.

connected.

2.

2. Two

Two

Two PWR

PWR

PWR pins,

pins,

pins, J1-

J1-

J1- 1

1

1 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-

1

1 to

to

to supply

supply

supply peripherals

peripherals

peripherals like

like

like alarm

alarm

alarm and

and

and contactor

contactor

contactor .

.

. Twist

Twist

Twist peripheral

peripheral

peripheral wires

wires

wires with

with

with PWR

PWR

PWR is

is

the

the preferred

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

alarm

alarm and

and

and Contactor

Contactor

Contactor coil

coil

coil driver.

driver.

3.

3. Kelly

Kelly

Kelly Ampmeter

Ampmeter

Ampmeter positive

positive

positive connect

connect

connect to

to

to 5V

5V

5V power

power

power supply

supply

supply of

of

of controller,

controller,

controller, negative

negative

negative to

to

to J1-2.

J1-2.

4.

4. 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

inactive .

.

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 ing

ing

ing power.

power.

power. O

O

O therwise

therwise

therwise it

it

it may

may

damage

damage the

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+.Please

B+.Please

B+.Please place

place

place precharge

precharge

precharge resistor

resistor

resistor on

on

on any

any

any breaker!

breaker!

breaker! It

It

It can

can

can cause

cause

damage

damage without

without

without it!!!

it!!!

Kelly

Kelly Full

Full

Full Bridge

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3.2.2

3.2.2 Standard

Standard

Standard Wiring

Wiring

Wiring of

of

of PM

PM

PM Motor

Motor

Motor Controlle

Controlle

Controlle r

r

Figure

Figure 5

5

5 :

:

: PM

PM

PM motor

motor

motor controller

controller

controller standard

standard

standard wiring

wiring

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Figure

Figure 6

6

6 :

:

: 120V

120V

120V motor

motor

motor controller

controller

controller standard

standard

standard wiring

wiring

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3.2.3

3.2.3 Communication

Communication

Communication Port

Port

A

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

configuration.

Figure

Figure 7

7

7 :

:

: standard RS232 interface

3.3

3.3 Installation

Installation

Installation Checklist

Checklist

Before operating the vehicle, complete the following checkout procedure s.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 keep 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 restarting .

• 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 operate . 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 both the PWR switch and the brake are off.

• Use well-insulated tools .

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Chapter

Chapter 4

4

4 Maintenance

Maintenance

There are no user-serviceable parts inside the controllers. Do not attempt to open the controller , or will void warranty. However, clea n ing 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 tools.

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, starting with battery positive.

• Discharge the capacitors in the controller by connecting a load (such as a contactor coil,

resistor 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. 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 or USB port .

• Use straight through RS232 cable or USB converter provide d by Kelly to connect the D9

connector to a host computer. Provide >18V (either J2 pin1 or J1 pin 1 ) to PWR. Wire power supply return to any RTN pin.

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

affect programming or configuration .

Download and setup the configuration software ：

http://www.newkellycontroller.com/support.php

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Table

Table 1:

1:

1: LED

LED

LED CODES

CODES

Green LED Code

Red LED Code

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!

Green and Red LED Keep On

1.

Software is upgrading.

2.

Supply voltage too low or battery too high 3 . The controller is damaged . Please contact Kelly for warrantee.

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 .

3.

Please note there could be 2% error with Overvoltage setting.

1,3

¤ ¤¤¤

Low voltage error

1.

The controller will attempt to clear the fault code automatically after 5 second if battery voltage return s 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 ℃ . 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

2,2

¤¤ ¤¤

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.

When controller’s temperature is over 100 ℃ . it will s top driving in order to protect itself.

2.

Stop driving and wait for temperature fall. T he controller will restart if temperature drops below

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8 0 ℃ .

2,4

¤¤ ¤¤¤¤

Throttle error at power up

1.

The throttle signal is higher than configured dead z o ne at power-on .

2.

The fault will disappear if restart s or release s throttle.

3,1

¤¤¤ ¤

Frequent reset

1. It can be caused by over current, bad motor, bad ground wiring or so.

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.

3,3

¤¤¤ ¤¤¤

Throttle short or open circuit when using 1-4v hall sensor throttle

1.

Check whether the throttle is short or open up.

2.

When the throttle is normal, restart will clear

the error.

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 chang ing direction.

4,1

¤¤¤¤ ¤

Over voltage at startup or regeneration

The controller won ’ t drive motor if detect s overvoltage at power up. It will cut back regen current or stop regen if detect s overvoltage during regen.

You

may set overvoltage threshold with GUI .

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

¤¤¤¤ ¤¤¤

M otor over temperature

1.The motor temperature is higher than configured max temperature. Controller will s hut down and wait for motor temperature drop ping.

2.Can change the temperature setting with configuration program.

T he Red LED flashes once at power on, then keeps o ff 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.

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Contact

Contact Us:

Us:

Kelly

Kelly Controls,

Controls,

Controls, LLC

LLC

Home

Home Page:

Page:

http://www. new kellycontroller.com

E-mail:

support@kellycontroller.com

Phone:

( 0 1) 224 637 5092

KEYA PM24201, PM36201, PM36101, PM24301, PM48201 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual