Kelly Controls LLC's blog

Kelly provide regen controller for series wound motors.

1 General functions
(1)Extended fault detection and protection. Red LED flashing code indicates fault sources, and Green LED indicates normal operation. Controller will shut down in some fault conditions.
(2)Built-in current loop and over current protection.
(3)Cutting back current at low temperature and high temperature to protect battery and controller. The current will ramp down quickly if controller temperature is higher than 80ﹾＣ, and shutdown at 100ﹾＣ.
(4)Thermal overload detection and protection to safeguard the motor from over temperature (designed using Silicon temperature sensors KTY83-122).
(5)Monitoring battery voltage. It will stop driving if battery voltage is too high. It will cut back then stop driving if voltage is going too low.
(6)Monitoring voltage during regen. It will cut back current then cut off regen if voltage is going too high.
(7)Multifunctional and configurable 3 switch inputs: brake switch, reversing switch, throttle or forward switch. Default to active-low, customizable active-high.
(8)3 analog inputs, 0-5V: Default to throttle input, brake input and motor temperature input.
(9)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).
(10)Configurable to limit max reverse speed to half of max forward speed.
(11)Configurable to limit max reverse current to half of max forward current.
(12)Configurable limit for motor current
(13)Capable of connecting to Kelly Ampmeter: positive to 5V power supply of controller, negative to J1-2.
(14)Provide power supply(5V) for hall sensors and other sensors.
(15)PWMable reverse alarm output.
(16)Main contactor driver. Cutting off the power if any fault is detected.
(17)Optional CAN Bus.
(18)Optional electronic unidirectional or bidirectional field drive for HSE controller.
(19)Customizable field current for HSE controller, less than 120A. Field driving capability is equivalent to armature for HSR controller.

2 Features
•Opto-isolated technology achieves stability.
•Intelligence with powerful microprocessor.
•Synchronous rectification, ultra low drop, and fast PWM to achieve very high efficiency.
•Voltage monitoring on voltage source 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. Support fan or water cooling.
•Rugged high current terminals, and rugged aviation connectors for small signal.
•Thermal protection.
•Configurable current or voltage mode for HSE field driver to achieve flexibility.
•Configurable high pedal protection: Disable operation if power up with high throttle.
•Brake switch is used to start regen.
•0-5V brake signal is used to command regen current.
•Standard PC/Laptop computer to do programming. No special tools needed.
•Provide free User Program. Easy to use. No cost to customers.
•Current multiplication: Take less current from battery, output more current to motor.
•Easy installation: 1-4V "Hall Active" throttle or "3 Wire" potentiometer(<100K) can work.

3 Specifications
•Frequency of Operation: 16.6kHz.
•Standby Battery Current depending on the model: usually less than 2mA.
•Controller input power, PWR: less than 10W.
•Controller supply voltage range, PWR, 8 to 30V
•Configurable battery voltage range, B+. Max operating range: 18V to 180V(depending on the model).
•Standard Throttle Input: 0-5 Volts(3-wire resistive pot), 1-4 Volts(hall active throttle).
•Analog Brake and Throttle Input: 0-5 Volts. 0-5V signal is produced by 3-wire pot.
•Reverse Alarm, Main Contactor Coil Driver, Meter.
•Full Power Temperature Range: 0ﹾＣ to 50ﹾＣ (controller case temperature).
•Operating Temperature Range: -30ﹾＣ to 90ﹾＣ , 100ﹾＣ shut down (controller case temperature).
•Motor Current Limit, 1 minutes: 300-1200A, depending on the model.
•Motor Current Limit, continuous:135-540A, depending on the model.

Kelly KIM series controller is designed for AC induction motors. It provide high efficient, smooth and quite controls for small and midsize electric vehicles, such as golf carts, go-carts, stacking cars, forklifts, hybrid vehicles, electric boats, as well as industry motor speed or torque 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 allows users to set parameters, conduct tests, and obtain diagnostic information quickly and easily.
Kelly KIM AC induction motor controllers range from 24V to 156V, 100A to 1000A.
http://kellycontroller.com/ac-induction-motor-controller-kim24v-72v-c-85.html

1 General functions
(1)Extended fault detection and protection. LED flashing for fault code indicates fault sources.
(2)Monitoring battery voltage. It will stop 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)Motor temperature input and protection. Configurable range.
(5)Cutting back current at low temperature and high temperature to protect battery and controller. The current will ramp down quickly if controller’s temperature is higher than 90Ｃ, and shut down at 100ﹾＣ. Low temperature current ramping down usually starts at 0ﹾＣ.
(6)The controller keeps monitoring voltage during braking. It will cut back braking current if voltage is going too high.
(7)Configurable to limit max reverse speed to half of max 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)Provide power supply (5V) for hall sensors and other sensors.
(10)3 switch inputs: Default to forward switch, brake switch and reversing switch. Closing to ground is to activate.
(11)3 analog inputs: Default to throttle input, brake input and motor temperature input.
(12)PWMable reverse alarm output.
(13)Main contactor driver. Cutting off the power if any fault is detected.
(14)Current meter to display both drive and regen current. Save shunt.
(15)Configurable 12V brake signal input, instead of motor temperature sensor.
(16)Thermal overload detection and protection to safeguard the motor from over temperature (designed using Silicon temperature sensors KTY83-122).
(17)Speed encoder input.
(18)The power supple of the controller is the standard battery voltage range.

2 Features
1)Intelligence with powerful microprocessor.
2)Synchronous rectification, ultra low drop and fast PWM to achieve very high efficiency.
3)Electronic reversing.
4)Voltage monitoring on 3 motor phases, bus, and power supply.
5)Voltage monitoring on voltage source 12V and 5V.
6)Current sense on all 3 motor phases.
7)Current control loop.
8)Hardware over current protection.
9)Hardware over voltage protection.
10)Configurable limit for motor current and battery current.
11)Low EMC.
12)LED fault code.
13)Battery protection: current cutback, warning and shutdown at configurable high and low battery voltage.
14)Rugged aluminum housing for maximum heat dissipation and harsh environment.
15)Rugged high current terminals, and rugged aviation connectors for small signal.
16)Thermal protection: current cut back, warning and shutdown on high temperature.
17)Decelerating speed according to the brake rate when brake switch is active.
18)Decelerating speed according to the brake rate at reverse. Configurable reversing accelerating function.
19)Support three braking modes: release throttle braking, brake switch braking or reversing
braking, analog signal variable braking. Configurable Decelerating Slip Frequency in
configuration program.
20)Support three-level speed: free (the controller will stop output), forward, and backward.
21)Configurable high pedal protection: Disable operation if power up with high throttle.
22)Current multiplication: Take less current from battery, output more current to motor.
23)Easy installation: 3-wire potentiometer can work.
24)Remote fault code LED driver.
25)Current meter output.
26)Standard PC/Laptop computer to do programming. No special tools needed.
27)User program provided. Easy to use. No cost to customers.

3 Specifications
•Frequency of Operation: 16.6kHz.
•Standby Battery Current: < 0.5mA.
•5V Sensor Supply Current: 40mA.
•Controller supply voltage range, PWR, 18V to 90V.
•Configurable battery voltage range, B+. Max operating range: 18V to 1.25*Nominal Voltage.
•Max output frequency can reach up to 255Hz.
•Standard Throttle Input: 0-5 Volts (3-wire resistive pot), 1-4 Volts (hall active throttle).
•Analog Brake and Throttle Input: 0-5 Volts. Producing 0-5V signal with 3-wire pot.
•Full Power Operating Temperature Range: 0ﹾＣ to 50ﹾＣ (controller case temperature).
•Operating Temperature Range: -30ﹾＣ to 90ﹾＣ, 100ﹾＣ shutdown (controller case temperature).
•Motor Current Limit, 1 minute: 100-500A, depending on the model.
•Motor Current Limit, continuous: 40A-200A, depending on the model.
•Max Motor Current : Configurable.