Kelly Jaguar series KAC-N AC Induction Motor Controller User Manual

Kelly Jaguar series KAC-N AC Induction Motor Controller

Specifications

• Series: Kelly Jaguar series KAC-N
• Devices Supported: KAC4812ND, KAC7218N, KAC7270NE, and more (refer to manual for full list)
• Version: 1.21
• Release Date: November 2023

Introduction

Overview

• This manual introduces the Kelly AC induction 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 centre of Kelly Controls.
• Kelly’s programmable AC induction motor controllers provide efficient, smooth and quiet controls for small and midsize electric vehicles, such as golf carts, go-carts, stacking cars, forklifts, hybrid vehicles and electric boats, as well as industrial motor speed control. It uses high-power MOSFETs and, SVPWM and FOC technology to achieve efficiencies of up to 99% in most cases. A powerful microprocessor brings in comprehensive and precise control to the controllers. It also allows users to adjust parameters, conduct tests, and obtain diagnostic information quickly and easily.
• People can program the KAC-N controller on PC software and Android App. There is one more choice for customers to program the KAC-N controller now. The APP software is based on a Tablet with Android OS. Customers may add a Z-TEK USB to RS232 cable for programming the KAC-N controller if they want to use the KAC-N App in an Android Tablet. KAC-N controller can provide Bluetooth function which can be used to connect the controller to Android Phone. Bluetooth is a separate device which is a
• plug-and-play device into the controller programming port.
• Both PC software and Android apps can provide one screen to monitor the controller parameters. Sometimes people can use a small Android Tablet as a display device. KAC-N controller can be connected by Bluetooth device on Android Phone or Tablet also.

General functions

1. Extended fault detection and protection. The beep sound pattern indicates the fault sources. Customers can read the error code or message in PC software or Android App also.
2. 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.
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. The controller keeps monitoring battery recharging voltage during regenerative braking, progressively cutting back current as battery voltage rises then cutting off regen altogether when voltage goes too high.
7. Maximum reverse speed and forward speed can be configured between 20% and 100 %respectively and separately.
8. A 4pin connector to RS232 converter and USB to RS232 cable allows for configuration, programming and software upgrades using a tablet which should be based on Android OS. People can do the same operation and configuration on PC software by using a standard USB to RS232 cable instead.(Recommend using USB to RS232 cable from Kelly directly)
9. Provision of a +5 volt and +12V output to supply various kinds of sensors, including Hall effective throttle or pedal type.
10. 3 switch inputs which are activated by connection to +12V. Default to forward switch, brake switch and reversing switch.
11. 2 analog 0-5V inputs that default to throttle input and motor temperature input.
12. Configurable motor over-temperature detection and protection with the recommended thermistor KTY84-130/150.
13. Dual Channel A/B encoder input to support the speed control.
14. The power supply of the controller is the standard battery voltage range.

Caution! Regeneration has a braking effect, but it should not replace the mechanical brake. A mechanical brake is still required to stop the vehicle. Regen is not a safety feature! To protect itself and the battery from overheating,controller may suddenly stop regen and release the brake without warning.

Features

1. Intelligence with powerful microprocessor.
2. Synchronous rectification, ultra-low drop and fast SVPWM and FOC to achieve very high efficiency.
3. Electronic reversing.
4. Voltage monitoring on 3 motor phases, bus, and power supply.
5. Voltage monitoring on voltage sources 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. Battery protection: current cutback, warning and shutdown at configurable high and low battery voltage.
13. Friendly high-current terminals, and waterproof connectors for small signal.
14. Thermal protection: current cut back, warning and shutdown at high temperature.
15. Decelerating speed according to the brake rate when the brake switch is active.
16. Decelerating speed according to the brake rate at reverse. Configurable reversing accelerating function.
17. Support three braking modes: release throttle braking, brake switch braking or reversing braking, and neutral braking. Configurable brake time and brake release time in the configuration program. Can program the regen amount in the user program for different regen modes.
18. Bidirectional anti-slip function(Optional) , Prevent the stationary vehicle from moving in the opposite direction. After the function is enabled, when the controller detects that the motor turns from a standstill to the opposite direction, it will drive the motor to provide some braking force, making the vehicle stop or slow down. The braking force can be set as required. Mainly used on ride-on floor sweepers and floor scrubbers.
19. Configurable high pedal protection: the controller will not work if a high throttle is detected at power on.
20. Current multiplication: Take less current from the battery, and output more current to the motor.
21. Easy installation: A 3-wire potentiometer can work.
22. Standard PC/Laptop computer to do programming. There is one more choice for customers to program the KAC-N controller. Standard Tablet with Android OS to do programming. Need a Z- TEK USB to RS232 cable for connecting the controller to APP program in the Tablet.
23. User program provided. Easy to use. User programs can be downloaded from our website for free.

Specifications

• Frequency of Operation: 10KHz
• Standby Battery Current: < 0.5mA.
• 5V Sensor Supply Current: 40mA.
• Configurable battery voltage range, B+.
• The max output frequency can reach up to 250Hz.
• Standard Throttle Input: 0-5 Volts (3-wire resistive pot), 1-4 Volts (hall active throttle).
• Full Power Operating Temperature Range: 0℃ to 70℃ (Mosfet temperature).
• Operating Temperature Range:-40℃ to 90℃, 100℃ shutdown (Mosfet temperature).
• Max Motor Current: Configurable.

Naming Regulations
The naming regulations of Kelly KAC-N AC induction motor controllers:

KAC7230N

• KAC: Kelly AC Induction motor controller based on SVPWM and FOC technology which is supposed to work with AC induction motor with dual channel A/B Encoder.
• 72:7 2V batteries. The rated voltage of the AC motor is 72V/1.414=50.9V
• N: The Controller has a grey plastic cover with a fuse. Dust and water are protected under sealed conditions, IP66. And KAC-N is based on an Aluminum based plate-type controller.

Kelly KAC-N AC Induction Motor Controller

Model| Nominal

Voltage

| Max Operating

Voltage

| Peak Current**

1 Minute

| Continuous

Current

---|---|---|---|---
KAC4812ND| 36-48V| 27-60V| 140A| Up to 100A
KAC4812N| 36-48V| 27-60V| 140A| 60A-100A
KAC4818N| 36-48V| 27-60V| 240A| 80A-130A
KAC4830ND| 36-48V| 27-60V| 280A| up to 160A
KAC4830N| 36-48V| 27-60V| 280A| 90A-150A
KAC7212ND| 48-72V| 36-86V| 140A| Up to 100A
KAC7212N| 48-72V| 36-86V| 140A| 50A-90A
KAC7215ND| 48-72V| 36-86V| 200A| Up to 110A
KAC7215N| 48-72V| 36-86V| 200A| 60A-110A
KAC7218N| 48-72V| 36-86V| 240A| 80A-120A
KAC7225N| 48-72V| 36-86V| 270A| 90A-130A
KAC7230ND| 48-72V| 36-86V| 280A| up to 150A
KAC7230N| 48-72V| 36-86V| 280A| 90A-135A
KAC7240N| 48-72V| 36-86V| 320A| 90A-150A
KAC7250ND| 48-72V| 36-86V| 360A| up to 190A
KAC7250NE| 48-72V| 36-86V| 360A| 120A-170A
KAC7260NE| 48-72V| 36-86V| 400A| 130A-180A
KAC7270ND| 48-72V| 36-86V| 450A| up to 225A
KAC7270NE| 48-72V| 36-86V| 450A| 150A-225A
KAC8418N| 48-84V| 40-100V| 240A| 80A-120A
KAC8430ND| 48-84V| 40-100V| 280A| up to 150A
KAC8430N| 48-84V| 40-100V| 280A| 90A-135A
KAC8445NE| 48-84V| 40-100V| 320A| 100A-160A
KAC8460NE| 48-84V| 40-100V| 400A| 130A-180A
KAC9650NE| 48-96V| 40-115V| 280A| 85A-140A

Note:

• Depends on the conductive heat sink.
• Peak current can be prolonged with additional heat sink, easily over 2 minutes.

Wiring and Installation

Mounting the Controller
The controller can be oriented in any position which should be as clean and dry as possible, 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 several screws. Applying silicon grease or some other thermal conductive material to the contact surface will enhance thermal performance.
Proper heat sinking and airflow are vital to achieve the full power capability of the controller.

The case outline and mounting holes’ dimensions are shown in below Figure.

Connections

Pin definition of KAC-N Controller

DJ7061Y-2.3-21 Pin Definition

• (33)CAN-H: ( Optional function) Greenish.
• (11)12V: 12V Source, with a total current not exceeding 20mA. Red
• (34)CAN-L: (Optional function) Brownish.
• (22) ECO: Low-speed switch function. Blue.
• (10) ACC: foot switch. Deep grey.

DJ7091Y-2.3-11 Pin Definition

• (3) Throttle: Throttle analog input, 0-5V. NavyGreen.
• (20) RTN: Signal return or power supply return. Black.
• (4) 5V: 5V supply output, <40mA. Purple.
• (12) FWD: Forward switch White.
• (11) 12V: 12V Source , with a total current not exceeding 20mA. Red.
• (14) REV_SW: Reverse switch input. Gray.
• (13) 12V brake switch. Brown.
• (8) Pulses speed output. Blue.
• (7) PWR: Controller power supply (input). Pink.

DJ7021-1.5-21 Pin Definition

• (1) Temp: Motor temperature sensor input. Raddle.
• (19) RTN: Signal return. Black

DJ7041-1.5-21 Pin Definition

• (21) RTN: Signal return. Black.
• (18) Encoder A phase output. Orange.
• (17) Encoder B phase output. Green.
• (11) 12V: 12V Source Pink.

Notes:

• All RTN pins are internally connected.
• Switch to 12V is active. The open switch is inactive.
• Must need a Dual A/B Channel Encoder to support speed control.

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. Lack of even one of these precharge resistors may severely damage the controller at switch-on.

Wiring of KAC-N Motor Controller

Figure 9: Standard Wiring for KAC-N Controller (Battery voltage can be used for controller supply)

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

Installation Check List
Before operating the vehicle, complete the following checkout procedures. Use error code as a reference as listed in Table 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 is off
• Use well-insulated tools.

• Make sure the wire is connected correctly
• Turn the PWR switch on.
• The 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. 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 Error code, and correct

Programmable Parameters

KAC-N Configuration program allows users to set parameters according to the vehicle’s actual working environment to be at its best.
There are three types of programmable parameters: vehicle control parameters, motor control parameters and controller parameters. The default parameters of the controller are not recommended for all applications. Make sure to set the proper parameters before making any test to avoid danger.
It is better if customers can provide the parameters of AC motor so that we can configure the controller for the motor before shipping out. We need the motor parameters below.

• Rated Voltage AC voltage or DC Voltage.For example,42VAC=60VDC. Rated power
• Rated speed(RPM)
• Rated frequency
• Motor poles
• Pulses of Dual Channel A/B Encoder

Vehicle Control Parameters

1. Low Volt: The min voltage of reporting this fault – Range 40~86, depending on the model. The controller will not operate when the battery voltage is near the value to protect the battery. Suggestion: Set according to the practical situation. By default, it is set at 40V.

2. Over Volt: The max voltage of reporting this fault – Ranges 40~86, depending on the model. The controller will not operate when the battery voltage is higher than the value to protect the battery and controller.
   Suggestion: Set according to the practical situation.
   By default, It is 80V for a 60V controller. It is 86V for 72V controller.Controller Rated voltage| Under Voltage Range (V)| Over Voltage Range(V)
   ---|---|---
   60V| 40~80| 40~80
   ---|---|---
   72V| 40~86| 40~86

3. Current Percent: Phase Current Percent. Range: 20~100
   Functional description: The max motor current is (The Value * Peak Current of the Controller). Suggestion: Factory default is 100%.

4. Battery Limit: Battery Limit Current, Limit the max value of Battery Current. Range: 20~100 Functional description: Set max battery current to protect the battery. A lower value means a lower battery output current and a better protective effect. But the excessively low value will affect acceleration.
   Suggestion: Factory default is 100%.

5. Battery weak: It is supposed to protect the batteries from over-discharging. When the battery voltage is at 1.15Low voltage setting value, the controller starts to reduce the battery current to the battery current setting. The range is 0-100%. For example, if you set the low voltage at 40V and the battery weak at 80%, the controller will start to reduce the current at 40V1.15=52.9V. The battery current will be reduced to 80%. If you set up the battery limit at 60% and motor current percentage at 50%, the final battery current is controller peak current50%60%80%=controller rated peak current24% after weakening.

6. TPS Low Err: Hall active pedal, if lower than the value, report the fault of TPS Type. Range: 0~20

7. TPS High Err: Hall active pedal, if higher than the value, report the fault of TPS Type. Range: 80~100
   As you may know, the output of the hall throttle from Kelly is about 0.86V to 4.2V.
   Our controller will report 3.3 error code if the output of the hall throttle is below 0.5V or above 4.5V by default.
   The controller will think the hall throttle is shorted or damaged if the output is beyond the range from 0.5V to 4.5V.
   You can adjust the threshold voltage below or above 0.5V. The controller will report the 3.3 code to protect the system according to different types of hall throttle.
   Because there are many different hall throttle suppliers in the world. The initial output can not be always in the range of 0.5V to 4.5V.
   But it doesn’t make any difference if you choose a 0-5V or 3-wire pot for the throttle type. That is to say, these two settings are only useful for hall active throttle or pedal when you choose throttle type at 2.
   As the same goes, it is valid to adjust the high threshold voltage above 4.5V or below 4.5V. Usually, the hall output voltage is 4.2V Max. If you adjust it to a lower value which is near 4.2V,it may trigger the error code in the normal way.

8. TPS Type: TPS Type, 1:0-5V 3-wire 0-5K pot,5K is normal,2K-20K can be used;2:Hall active throttle or pedal. Range: 1~2

9. TPS Dead Low: TPS Dead Zone Low. Range: 5~40
   Functional description: Set throttle effective starting point
   Suggestion: Set according to the practical situation, the factory default is 20%*5V=1.0V.

10. TPS Dead High : TPS Dead Zone High. Range: 60~95
    Functional description: Set throttle effective ending point
    Suggestion: Set according to the practical situation, the factory default is 80%*5V=4.0V.

11. TPS Fwd MAP: It is used to adjust the acceleration rate in the forward direction.

12. TPS Rev MAP: It is used to adjust the acceleration rate in a reversing direction.

13. Max output Fre : Max output frequency of the controller. Unit: Hz
    Functional description: It will affect the top speed of the motor.
    Suggestion: Set according to the practical situation, the factory default is 250Hz.Please don’t set it 250Hz above.Range:1-250Hz

14. Max Speed: Max Speed [rpm]. Range: 0~7500 By default, it is set at 4500.

15. Max Fwd Speed %: The forward speed of the percentage of maximum speed.

16. Range : 20~100 By default, it is set at 100%

17. Max Rev Speed %: The reverse speed of the percentage of maximum speed.

18. Range : 20~100 By default,it is set at 100%

19. Start-up H-Pedal:
    Value range : Enable and Disable
    Functional description: If enabled, the controller will detect the current pedal status at power up. If the throttle gets effective output, the controller will report fault and not operate.
    Suggestion: Set according to the practical situation, factory default is Enable.

20. Brake H-Pedal: Releasing Brake High Pedal Disable
    Value range: Enable and Disable
    Functional description: If enabled, the controller will detect the current pedal status when the brake. If the throttle has an effective output, the controller will report fault and not operate.

21. Suggestion: Set according to the practical situation, the factory default is disabled.

22. NTL H-Pedal: Neutral position High Pedal Disable. Only useful when The gears switch function is enabled.
    If enabled, the controller will detect the current pedal position or signal When the switch is in a neutral position.
    If the throttle gets an effective output signal, the controller will not operate and report fault code. Suggestion: Set according to the practical situation, the factory default is disabled.

23. Foot Switch
    Value range: Enable and Disable
    Functional description: If enabled, the foot switch will be activated. The controller will not accept the throttle signal if the foot switch is turned off. Please see Figure 4.1.
    Suggestion: Set according to the practical situation, the factory default is disabled.

24. Exchange Encoder phase

25. Exchange Motor Phase
    Usually, the controller has been configured according to the motor parameters before shipping out. The motor parameters are provided by customers. We also can find the parameters from the nameplate of the motor.
    If the motor still can not run or run in the opposite direction. Please use the instructions below.

26. We need to know the structure of the car.

27. Motor: Most of the motors have similar parameters in the marketing. So we just need to know the most important parameters.
    They are rated voltage and Pulses of Encoder. We need to know if the rated voltage is DC or AC side. Usually, the pulse of the encoder is 48 or 64. The encoder can work from 5-12V. By default, it is 12V for the encoder on the KAC controller. Please check the thermistor type. By default, the KAC controller can support KTY84-130 or 150.

28. The I/O port: It is about throttle type and throttle voltage. Usually, it is a hall active type throttle under a 5V source.
    By default, we used 12V to activate the brake switch, forward switch, reversing switch etc.12V is provided by the KAC controller. You also can customer external 12V as long as this 12V source has the same ground as the controller.

29. There is a speed signal(Pulse-type) from the controller for the speedometer. It is 4 pulses/rev by default.

30. Please hook up the controller according to the wiring diagram in the user manual.

31. Testing without load on the motor shaft.

32. Please make sure the car or motor is off the ground. Please turn on the power supply. Please connect the controller to the user program on the computer or Android Tablet. Please fill in the basic motor parameters write them into the controller and reset the power supply.

33. Please open the monitor screen in the user program. Please turn the car at neutral gear so that the motor will not run at all. Please check each I/O port and analog signal in the monitor screen. Please rotate the motor by manually a little to see if the encoder signal is variable.

34. Please make sure the car is in neutral gear. Please open the monitor screen. Please don’t press the throttle pedal. Please check the AD value of the throttle signal and make a record. Please press the throttle to the max position, please record the AD value of the throttle accordingly.
    Please use AD/255 to define the throttle effective starting and ending position. Usually, we take 20% for the throttle-effective starting position and 80% for the throttle-effective ending position.

35. Please disable the anti-slip function in the first parameter screen.
    KAC controller only can work with F-N-R control. Customers must use the forward switch and reversing switch at the same time to change the motor direction.
    Please turn on the forward switch and check the monitor screen to see if the Setting Dir is at 0. Then please turn on the reversing switch to see if the Setting Dir is at 1 in the user program. You may not turn on or off both the forward switch and the reversing switch at the same time.
    If both is OK, we have already found the correct switch signals for the forward, neutral and reversing switch. It must fit this operation to find the correct driving direction. Otherwise, we need to check the wiring and settings again.
    Please make sure the car is in neutral gear. Please try to rotate the motor wheel or shaft in the forward direction manually. Please check if the Actual Dir value is at 0.
    Please try to rotate the motor wheel or shaft in the reversing direction. Please check if the Actual Dir value is at 1. If both are yes, the direction is what we expected. Everything is fine.
    If the result is just the opposite, please return to the page of Vehicle parameter, Please change the current status of the Exchange Encoder Phase in the user program. That is to say, if the Exchange Encoder Phase is disabled, please enable it. If the Exchange Encoder Phase is enabled, please disable it. Please reset the power supply to activate the settings after the current status of the Exchange Encoder Phase is changed.
    Please turn the forward switch on and press the throttle pedal a little bit. If the motor can accelerate in a forward direction gradually, everything is fine. If the motor accelerates in the reversing direction slowly, you need to return to the Vehicle Parameter page again, please change the current status of the Exchange Motor Phase item in the user program. Please test the motor driving again, if everything is fine, please turn the power supply off, Please try to do more testing on the road further.

Motor Parameters

1. Motor Poles: Motor Poles, The pair pole number*2. Range: 2~128
   Suggestion: Set according to the real motor poles on the nameplate of the motor, factory default is at 4.

2. Speed Sensor Type: 1:Dual Channel A/B Encoder2:Hall, 3:Resolver, 4:Line Hall. Range: 1~4 Different sensors type. By default, it is set at 1.
   Usually KAC controller should work with an AC induction motor with an Encoder

3. Resolver Poles: Resolver Poles, The pair pole number*2. Range: 2~32
   It is only used for the Resolver sensor type.

4. Motor Temp Sensor: Motor Temp Sensor, 0:None, 1:KTY84-130 or 150. Range: 0~1
   High Temp Cut Out °C : Motor High Temp Cut Out, nominal value 130°C. Range: 60~170 Resume °C: Motor High Temp Resume Temp, nominal value 110°C. The controller will resume work when the motor temp is at 110 degrees inside. Range: 60~170

5. High Temp Str: If the temp of the motor is high, the controller will try to reduce the current to protect the motor. High Temp Str is at which temperature to start to reduce the current.
   By default, it is set at 100 degrees.

High Temp Weak %: How many amps will be reduced when the temp is at the High Temp Str setting value? If you set it at 20%, it means 20% of driving current will be reduced. The left current is 80% of driving.

Controller Control Parameters

1. RLS_TPS Brk %: RLS TPS Braking Percent, the per cent of Releasing Pedal BRK in max braking. Range: 0~50
   This is used to adjust the regeneration current of the releasing throttle regeneration mode type. The regeneration will happen as long as the throttle is released completely.
   Factory set is 0

2. NTL Brk %: NTL Braking Percent, the percent of Neutral Braking in max braking. Range: 0~50
   Only useful when you enable The gear switch in the user program.
   The regen will happen when you turn the F-N-R switch from Forward or backward to Neutral position. Factory set is 0

3. Accel Time: Accel Time, the time of TPS Torque from 0 to max, accuracy 0.1s, 5 is equal to 0.5s. Range: 1~250
   Factory set is 10

4. Accel Rls Time: Accel Release Time, the time of TPS Torque from max to 0, accuracy 0.1s. Range: 1~250
   Factory set is 1

5. Brake Time: Brake Time, the time of Brake Torque from 0 to max, accuracy 0.1s. Range: 1~250
   Factory set is 15

6. Brake Rls Time: Brake Release Time, the time of Brake Torque from max to 0, accuracy 0.1s. Range: 1~250
   Factory set is 1

7. BRK_SW Brk %: BRK_SW Braking Percent, the percent of BRK_SW in max braking. Range: 0~50
   The brake switch regeneration mode. You have to turn on the brake switch after the throttle is released for the regeneration to occur.
   Factory set is 10

8. Change Dir brake : Value range:0-100

   • You can change the motor direction from a forward direction to a reversing switch while the motor is still running on the KAC controller by default, and vice versa. This item is used to set the regen current to help the motor change direction quickly.
   • If you want to get a swift direction, you may enable the Change Dir brake item in the user program.
   • It will help the motor change direction of the motor quickly after you change the switch signal from forward to reversing or from reverse to forward.

9. Suggestion: The factory default is Disable

10. Compensation %: It is used to help the motor can climb the slope well even if you just press the throttle pedal a little bit.

11. IVT Brk Max Motor: Max motor speed limiting setting.

12. IVT Brk Min Motor: Min motor speed limiting setting.
    You can change the motor direction from a forward direction to a reversing switch while the motor is still running on the KAC controller by default, and vice versa. In which speed range, you can operate the motor controller in this way. For example, if we up set IVT Brk Max Motor at 100RPM and IVT Brk Min Motor at 50RPM, that is to say, you only can change the motor direction while the motor is still running when the speed range is between 50RPM and 100RPM.If the speed range is beyond this range, the controller will not allow to change the motor direction while the motor is still running.

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 cleaning of the controller should be carried out.
The controller is a high-powered 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 jewellery. 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 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. 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.
• Do not connect B+, throttle and so on. The controller may display fault code, but it doesn’t affect programming or configuration.
• Use a straight-through RS232 cable or USB converter provided by Kelly to connect to a host computer. Provide >+18V to PWR(pin7). Wire power supply return to any RTN pin.
• KAC controller needs an SM-4A to DB9(RS232) converter and USB to RS232 cable to communicate with the user program on a PC or App on an Android Tablet. You may use the Z-TEK USB to RS232 cable if you want to use the program in the Tablet.

Download the free configuration software from: http://www.kellycontroller.com/support.php

Caution:

• Make certain that the AC Induction motor is stopped 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.
• You may try to find the correct driving direction before running the motor.

Table 1: Error CODES

Beep sound Codes

Beep keeps sounding|  | 1.      Software still upgrading or Identification angle operation

2.      Throttle signal is higher than the preset ‘dead zone’ at Power On. Fault clears when throttle is

released.

---|---|---

Beep sound Codes

like a temporary over-current, momentarily high or low battery voltage. This can happen during normal

operation.

1,4|  | Over temperature| The controller temperature has exceeded 100℃. The controller will be stopped but will restart when

temperature falls below 80℃.

1,6|  | Reserved|
1,7|  | Speed sensor error| Please check the wiring or connection of encoder of the motor

The encoder sensor could be damaged

1,9|  | Low voltage error| The controller will clear after 5 seconds if battery volts returns to normal. If the voltage between B+ and B- is lower than the Low voltage setting, the controller will report this error code.

Check battery volts & recharge if required.

1,10|  | Over voltage error| Battery voltage is too high for the controller. Check battery volts and configuration.

Regeneration over-voltage. The controller will have cut back or stopped regen.

This was only accurate to ± 2% upon Overvoltage

setting.

1,11|  | Motor

over-temperature

| Motor temperature has exceeded the configured

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

1,13|  | Acceleration throttle is malfunction| When the throttle is repaired, a restart will clear the fault.

The throttle type choice can not match the actual

throttle you are using.

Customers may read error messages in PC software or Android Tablet

Contact Us:
Kelly Controls

• Home Page: http://www.KellyController.com
• Download the user manual, instructions and user program: www.kellycontroller.com/support.php
• E-mail:[email protected]
• Phone: (01) 224 637 5092

FAQ

• Q: How do I troubleshoot error codes?
  • A: Refer to Table 1 in the manual for a list of error codes. Additionally, beep sound codes are provided for easy identification of issues. If you encounter any errors, cross-reference with the manual for troubleshooting steps.
• Q: How can I contact support?
  • A: Contact information is available at the end of the manual. Reach out to our support team for any queries or assistance regarding the Kelly Jaguar series KAC-N AC Induction Motor Controller.

References

• Kelly Controls - Motor Controllers, EV Parts

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