Kelly Controls SPM4812S Kelly SPM Mini Full Bridge 4Q Permanent Magnet Motor Controller User Manual

Kelly Controls SPM4812S Kelly SPM Mini Full Bridge 4Q Permanent Magnet

Motor Controller

Product Information

The Kelly SPM Mini Full Bridge 4Q Permanent Magnet Motor Controller is a motor controller that provides fast and reliable electronic direction control. It is a full bridge or 4-quadrant controller with extended fault detection and protection. The controller also features monitoring of battery voltage, built- in current loop and over-current protection, configurable motor temperature protection range, and current cutback at low and high temperatures to protect the battery and controller.

Product Usage Instructions

1. Chapter 1: Introduction

   • Before using the motor controller, read the user manual carefully and thoroughly. If you have any questions, contact the support center of Kelly Controls.

2. Chapter 2: Features and Specifications

   • Extended fault detection and protection: The LED flashing pattern indicates the fault sources.
   • Monitoring battery voltage: Stop driving if the battery voltage is too high or too low.
   • 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.

3. Chapter 3: Wiring and Installation
   

   • Follow the instructions provided in this chapter to mount the motor controller properly.
   • Refer to the user manual for detailed instructions on how to make the necessary connections for the motor controller.
   • Use the installation checklist in this chapter to ensure that all necessary installation steps have been completed.

4. Chapter 4: Maintenance
   

   • Refer to the user manual for instructions on how to clean the motor controller properly.
   • Follow the instructions in this chapter to configure the motor controller according to your requirements.
   • Refer to Table 1 in the user manual for LED codes and their meanings. For further assistance or inquiries, please refer to the contact information provided in the user manual.

Introduction

Overview

• This manual introduces the Kelly SPM motor controllers’ features, their installation, and their maintenance. Read the manual carefully and thoroughly before using the controller. If you have any questions, please contact the support center of Kelly Controls.
• Kelly’s programmable motor controllers provide efficient, smooth, and quiet controls for electric vehicles like golf carts, go-carts, electric motorcycles, scoo ters, forklifts and hybrid vehicles, as well as electric boats and industrial motor speed control. It uses high power
• MOSFET’s and, PWM to achieve efficiencies of up to 97% in most cases. A powerful microprocessor brings in comprehensive and precise contro l to the controllers. It also allows users to adjust parameters, conduct tests, and obtain diagnostic information quickly and easily.
• Kelly’s SPM motor controller is a full bridge or 4-quadrant controller. It provides fast and reliable electronic direction c ontrol. There is no arc, spark, or life limit on motor direction changes.

Features and Specifications

General functions

1. Extended fault detection and protection. The LED flashing pattern indicates the fault sources.
2. Monitoring battery voltage. Stop driving if the battery voltage is too high or too low.
3. Built-in current loop and over-current protection.
4. Configurable motor temperature protection range.
5. Current cutback at low temperature and high temperature to protect battery and controller. The current begins to ramp down at 90 case temperature , shutting down at 100
6. Two RS232 ports. Both can be used for configuration.
7. An RS232 port allows for configuration, programming, and software upgrades using the free Windows GUI with your PC.
8. Provision of a +5 volt and a +12 volt output to supply various kinds of sensors, including Hall effect type.
9. 3 switch inputs which are activated by connection to Ground. Default to throttle switch, brake switch, and reversing switch.
10. 3 analog 0 5V inputs that default to throttle input, brake input, and motor temperature input.
11. Pulsed reverse alarm output.
12. Main contactor driver. Cutting off the power if any fault is detected.
13. The current meter can display both drive and regen current. Save shunt.
14. Configurable boost switch. Enables the maximum output power achievable if the switch is turned on.
15. Configurable economy switch. Limits the maximum current to half if the switch is turned on.
16. Maximum reverse power is configurable to half power.
17. Enhanced regen brake function. A novel ABS technique provides powerful and smooth regen.
18. Configurable 12V brake signal input, in lieu of motor temperature sensor.
19. Optional joystick throttle. A bi-symmetrical 0 5V signal for both forwarding and reversing.
20. Configurable motor over-temperature detection and protection with the recommended thermistor KTY84 130.
21. Using battery powered.
22. Optional supply voltage 8V 30V.

Features

1. Intelligence with powerful microprocessor.
2. Synchronous rectification, ultra-low drop, and fast PWM to achieve very high efficiency.
3. Electronic reversing, no reversing contactor needed, fast direction change, high reliability, and efficiency, low noise, no arc, no wearing, no life limit, easy maintenance.
4. Voltage monitoring on voltage sources 12V and 5V.
5. Current limit and torque control. Configurable torque mode and speed mode.
6. Low EMC.
7. LED fault code.
8. Battery protection: current cutback, warning, and shutdown at configurable high and low battery voltage.
9. Rugged aluminum housing for maximum heat dissipation and harsh environment.
10. Rugged high current terminals, and rugged aviation connectors for small signals.
11. Thermal protection: current cut back, warning, and shutdown at high temperature.
12. Configurable high pedal protection: the controller will not work if a high throttle is detected at power on.
13. The brake switch is used to start the regen.
14. Support three modes of regenerative braking: brake switch regen, release throttle regen, and 0 5V analog signal variable regen.
15. A standard PC/Laptop computer is used to do programming. No special tools are needed.
16. User program provided. Easy to use. No cost to customers.
17. No adjustment.

Specifications

1. Frequency of Operation: 16.6kHz.
2. Stand by Battery Current: < 0.5mA.
3. 5V Sensor Supply Current: 40mA.
   • Controller supply voltage range, PWR, 18V to B+
   • Supply Current, PWR,150mA.
4. Standard Throttle Input: 0 5 Volts(3 wire resistive pot), 1 4 Volts(hall active throttle).
5. Analog Brake and Throttle Input: 0 5 Volts.
   • Reverse Alarm, Main Contactor Coil Driver, Meter.
6. Full Power Temperature Range: 0 to 50 ℃℃(controller case
7. Operating Temperature Range: 30 to 90 100 shutdowns (controller case temperature).
8. Max Battery Current: Configurable.

Kelly SPM Mini Full Bridge 4Q PM Motor Controller

Model| 1 Minute Boost

Current(Amp)

| Continuous

Current(Amp)

| Nominal

Voltage(Volt)

| Max Operating

Voltage(Volt)

SPM4812S| 120| 50| 36-48| 30-60
SPM4818S| 200| 80| 36-48| 30-60
SPM7212S| 120| 50| 48-72| 40-86
SPM7218S| 200| 80| 48-72| 40-86

Wiring and Installation

Mounting the Controller

• The controller can be oriented in any position which should be as clean and dry as possible , and if necessary, shielded 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 grease or some other thermal conductive material to contact surface will enhance thermal performance.
• Proper heat sinking and airflow are vital to achieving the full power capability of the controller.
• The case outline and mounting holes ’ dimensions are shown in the below Figure.

DJ7091Y-2.3-11 Pin Definition

1. (14) REV_SW: Reverse switch input. Orange
2. (6) RTN: Signal return or power supply return. Black
3. (12) FWD: Forward switch White
4. (11) 12V: 12V Source Red
5. (9) Relay: Main contactor driver. Blue
6. (7) PWR: Controller power supply (input). Pink
7. (10) Alarm: To drive reverse beeper, <200mA. Yellow

DJ7091Y-2.3-21 Pin Definition

1. (15) Micro_SW: Throttle switch input. Gray
2. (3) Throttle: Throttle analog input, 0-5V. Dark Green
3. (1) BRK2: 12V Brake switch input or Motor temperature sensor input. Raddle.
4. (20) RTN: Signal return. Black
5. (8) Meter: Current meter, <200mA. Dark Blue
6. (13) BRK_SW: Brake switch input. Brown
7. (4) 5V: 5V supply output, <40mA. Purple
8. (2)BRK_AN: Brake analog input, 0-5V. Dark Gray
9. (22)Reservation. Green

Notes:

1. All RTN pins are internally connected.
2. Kelly Ammeter positive connects to the 5V power supply of the controller, negative to Dark Blue wire.
3. The switch to the ground is active. The open switch is inactive.

Caution:

• Do not apply power until you are certain the controller wiring is correct and has been double-checked. Wiring faults will damage the controller.
• Ensure that the B wiring is securely and properly connected before applying power.
• The preferred connection of the system contactor or circuit breaker is in series with the B+ line.
• All contactors or circuit breakers in the B+ line must have precharge resistors across their contacts. L a ck of even one of these precharge resistors may severely damage the controller at switch on.

Wiring of SPM Controller

• Standard wiring of SPM controller

Figure 4: SPM controller standard wiring (Battery voltage ca n be used for controller supply Optional wiring of SPM controller The output signal of the pin is for Kelly current meter.
Figure 5: Wiring of current meter pin
The 12V input signal of the pin supplies the second braking function of the controller.

Communication Port
A 4-pin connector to the RS232 port is provided to communicate with the host computer for calibration and\ configuration.

Installation Check List
Before operating the vehicle, complete the following checkout procedure. Use LED code as a reference as listed in T able 1.

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 the PWR switch and the brake are off
• Use well-insulated tools.
• Prohibit trying to connect the controller to the user program while the motor is still running, let alone change the settings in the user program.
• Make sure the wire is connected correctly
• Turn the PWR switch on. The Green LED stays on steadily and the Red LED turns off when the controller operates normally. If this does not happen, check the continuity of the PWR and return.
• The fault code will be detected automatically at restart.
• With the brake switch open, select a direction and operate the throttle. The motor should spin in the selected direction. Verify wiring or voltage and the fuse if it does not. The motor should run faster with increasing throttle. If not, refer to the Table 1 LED code, and correct the fault as determined by the fault code.
• Take the vehicle off the blocks and drive it in a clear area. It should have smooth acceleration and good power.

Maintenance

• There are no user-serviceable parts inside the controllers.
• Do not attempt to open the controller as this will void your warranty. However, periodic, exterior clea n ing of the controller should be carried out.
• The controller is a high power ed device. When working with any battery-powered vehicle, proper safety precautions should be taken that include, but are not limited to, proper training, wearing eye protection, and avoidance of loose clothing, hair, and jewelry. Always use insulated tools.

Cleaning

Although the controller requires virtually no maintenance after proper 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 horn) across the controller‟s B+ and B- terminals.
• Remove any dirt or corrosion from the bus bar area. The controller should be wiped with a moist rag. Make sure that the controller is dry before reconnecting the battery.
• Make sure the connections to the bus bars, if fitted are tight. To avoid physically stressing the bus bars use two, well-insulated wrenches.

Configuration

• You can configure the controller with a host computer through either an RS232 or USB port.
• Disconnect motor wiring from the controller for configuring existing parameters in the user program or Android APP. If this operation is too much extra job for you, please make sure the motor is stopped before programming.
• The controller may display fault code, but it doesn’t affect programming or configuration it will affect the Identification angle operation. Please try to eliminate the error codes before the Identification angle operation.
• Use a straight-through RS232 cable or USB converter provided by Kelly to connect to a host computer. Provide > 18V to PWR ( 7). Wire power supply return (supply to any RTN pin.

Caution:

• Make certain that the motor is connected before trying to run the configuration software.
• Configuration software will be regularly updated and published on the website. Please
• Update your Configuration Software regularly. You must uninstall the older version before updating.
• Please try to use the Identify function for the motor and hall sensors in the user program

Table 1: LED CODES

Green LED Codes

2.  Supply voltage too low or battery too high

3.  The controller is damaged. Contact Kelly about a warranty repair.

Red LED Codes

controller. Check battery volts and configuration.

2.     Regeneration over-voltage. Controller will have cut back or stopped regen.

3.     This only accurate to ± 2% upon Overvoltage

setting.

1,3| ¤| ¤¤¤| Low voltage error| 1.  The controller will clear after 5 seconds if battery volts returns to normal.

2.  Check battery volts & recharge if required.

1,4| ¤| ¤¤¤¤| Over temperature warning| 1.  Controller case temperature is above 90℃. Current will be limited. Reduce controller loading or switch Off until the controller cools down.

2.  Clean or improve the heatsink or fan.

2,2| ¤¤| ¤¤| Internal volts fault| 1.     Measure that B+ & PWR are correct when measured to B- or RTN.

2.     There may be an excessive load on the +5V supply caused by too low a value of Regen or throttle potentiometers or incorrect wiring.

3. The controller is damaged. Contact Kelly about a

warranty repair.

2,3| ¤¤| ¤¤¤| Over Temperature| The controller temperature has exceeded 100℃. The

controller will be stopped but will restart when the temperature falls below 80℃.

2,4| ¤¤| ¤¤¤¤| Throttle error at

power-up

| The throttle signal is higher than the preset „dead zone‟ at

Power On. The Fault clears when the throttle is released.

3,1| ¤¤¤| ¤| Frequent reset| May be caused by over-voltage, bad motor intermittent earthing problems, bad wiring, etc.
3,2| ¤¤¤| ¤¤| Internal reset| May be caused by some transient fault condition like a temporary over-current, momentarily high or low battery voltage. This can happen during normal

operation.

3,3| ¤¤¤| ¤¤¤| Hall throttle is open

or short-circuit

| When the throttle is repaired, a restart will clear the

fault.

3,4| ¤¤¤| ¤¤¤¤| Non-zero throttle on| The controller won’t allow a direction change unless the
 |  | direction change| throttle or speed is at zero. The fault clears when the throttle

is released.

---|---|---|---
4,1| ¤¤¤¤    ¤| Regen or Start-up over-voltage| The motor drive is disabled if an over-voltage is detected at start-up or during regen. The voltage threshold detection level is set during configuration. The max threshold is about 1.25 times of controller-rated voltage. I.e. you may set a threshold lower than 60V for

48V controller.

4, 3| ¤¤¤¤    ¤¤¤| Motor

over-temperature

| The motor temperature has exceeded the configured

maximum. The controller will shut down until the motor temperature cools down.

The Red LED flashes once at power on as a confidence check and then normally stays Off. “1, 2” means the Red flashes once and after a second pause, flashes twice. The time between two flashes is 0.5 seconds. The pause time between multiple flash code groups is

two seconds.

Contact Us

• Kelly Controls Inc Home Page:
  • http://www.KellyController.com.
• Download the user manual, instructions, and user program:
  • www.kellycontroller.com/support.php.
• Email:
  • Sales@Kelly
  • Controls.com.
• Phone:
  • (01) 224 637 5092

Devices Supported:

• SPM 4812S
• SPM 7212S
• SPM 48 18S
• SPM 72 18 S

References

• Kelly Controls - Motor Controllers, EV Parts
• Kelly Controls - Motor Controllers, EV Parts

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