Kelly AC Induction Motor Controller

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.

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 90���C, 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.

Kelly KIM AC Induction Motor Controller


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