Kelly HPM High Power Full Bridge Permanent Magnet DC Motor Controller

General Functions

• Extended fault detection and protection. The LED flashing pattern indicates the fault sources. Green LED indicates normal operation. Controller will shut down in some fault conditions.
• 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.
• Built-in current loop and over current protection.
• Configurable motor temperature protection range.
• Current cutback at low temperature and high temperature to protect battery and controller. The current begins to ramp down at 90°C case temperature, shutting down at 100°C.
• Two RS232 ports. Both can be used for configuration.
• 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).
• Provision of a +5 volt output to supply various kinds of sensors, including Hall effect type.
• 4 switch inputs which are activated by connection to Ground. Default to throttle switch, brake switch, reversing switch and Boost/Economy switch input.
• 3 analog 0-5V inputs that default to throttle input, brake input and motor temperature input.
• Pulsed reverse alarm output.
• Main contactor driver. Cutting off the power if any fault is detected.
• Current meter to display both drive and regen current. Save shunt.
• Configurable boost switch. Enables the maximum output power achievable if the switch is turned on.
• Configurable economy switch. Limits the maximum current to half if the switch is turned on.
• Maximum reverse power is configurable to half power.
• Enhanced regen brake function. A novel ABS technique provides powerful and smooth regen.
• Configurable 12V brake signal input, in lieu of motor temperature sensor.
• Optional joystick throttle. A bi-symmetrical 0-5V signal for both forwarding and reversing.
• Configurable motor over-temperature detection and protection with the recommended thermistor KTY84-130.
• Using battery-powered.
• Optional CAN bus.
• Supply voltage 8V-30V.

Features

• Opto-isolated technology achieve stability.
• Intelligence with powerful microprocessor.
• Synchronous rectification, ultra low drop, and fast PWM to achieve very high efficiency.
• Electronic reversing, no reversing contactor needed, fast direction change, high reliability and efficiency, low noise, no arc, no wearing, no life limit, easy maintenance.
• Voltage monitoring on voltage source 12V and 5V.
• Current limit and torque control. Configurable torque mode and speed mode.
• 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. 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.
• Support three modes of regenerative braking: brake switch regen, release throttle regen, 0-5V analog signal variable regen.
• An RS232 port allows for configuration, programming and software upgrades using the free Windows GUI with your PC.
• Standard PC/Laptop computer is used to do programming. No special tools needed.
• User program provided. Easy to use. No cost to customers.
• No adjustment.

Specifications

• Frequency of Operation: 16.6kHz.
• Standby Battery Current depending on the model: usually less than 2mA.
• 5V Sensor Supply Current: 40mA.
• Controller supply voltage range, PWR, 8 to 30V (24V preferred)
• Controller input power, PWR: less than 10W.
• Standard Throttle Input:
  • 0-5 Volts (3-wire resistive pot)
  • 1-4 Volts (hall active throttle)
• Analog Brake and Throttle Input: 0-5 Volts.
• Reverse Alarm, Main Contactor Coil Driver, Meter.
• Full Power Temperature Range: 0°C to 50°C (controller case temperature).
• Operating Temperature Range: -30°C to 90°C , 100°C shutdown (controller case temperature).
• Motor Current Limit, 1 minutes: 300A-800A, depending on the model.
• Motor Current Limit, continuous: 135A-400A, depending on the model.
• Max Battery Current: Configurable