Kelly Jaguar Series AC Induction Motor Controller

Introduction

This manual provides essential information for the installation, operation, maintenance, and troubleshooting of your Kelly Jaguar series AC induction motor controller. The Jaguar series controllers are designed for various applications, offering a modest size and comprehensive functionality. They feature surface mount MOSFETs on an aluminum PCB for superior heat dissipation and are IP66 rated for waterproof protection.

Specifications

The Kelly Jaguar series motor controllers come in various models with different voltage and current ratings. Below is a detailed table of specifications for the available models, followed by general technical specifications and mounting dimensions.

Note:
*Depends on conductive heat sink.
**Peak current can be prolonged with additional heat sink, easily over 2 minutes.

General Technical Specifications

• Frequency of Operation: 10KHz
• Standby Battery Current: < 0.5mA
• 5V Sensor Supply Current: 40mA
• Configurable Battery Voltage Range: B+
• Max Output Frequency: 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

Mounting Dimensions (in millimeters)

Setup and Installation

Proper installation and initial configuration are crucial for optimal performance and safety. Follow these guidelines for setting up your Kelly Jaguar series motor controller:

1. Physical Installation: Mount the controller securely, ensuring adequate airflow for models without liquid cooling or proper connection to a conductive heat sink as indicated in the specifications. Refer to the provided mounting dimension diagrams for your specific model.
2. Wiring Connections: Connect the main power cables (B+, B-, U, V, W) using M5 bolts as specified. Ensure all connections are tight and secure.
3. Sensor and Switch Inputs:
   • Connect your throttle (0-5V 3-wire resistive pot or 1-4V Hall active throttle) to the designated analog input.
   • Utilize the +5V and +12V outputs to power various sensors as needed.
   • Connect switch inputs (e.g., forward, brake, reversing) which are activated by connection to +12V.
   • For motor over-temperature protection, connect the recommended KTY84-130/150 thermistor to the designated analog input.
   • If speed control is required, connect a Dual Channel A/B encoder to the corresponding input.
4. Programming and Configuration:
   • The controller can be configured and programmed using a standard PC/Laptop computer or an Android-based tablet.
   • For PC connection, use a standard USB to RS232 cable. For Android tablets, a Z-TEK USB to RS232 cable is required.
   • Download the user program from the official Kelly website. This software allows for setting parameters such as motor current limits, battery current limits, speed ranges, and braking modes.

Operating Instructions

Once installed and configured, the Kelly Jaguar series motor controller provides precise control over your AC induction motor. Here are key operational aspects:

1. Power On: Ensure the battery voltage is within the configurable range. The controller will perform self-diagnostics upon power-up.
2. Throttle Control: Use the connected throttle (0-5V or 1-4V Hall type) to control motor speed. The controller features a current control loop for smooth acceleration.
3. Speed Configuration: Maximum forward and reverse speeds can be individually configured between 20% and 100% using the programming software.
4. Braking Modes: The controller supports three braking modes:
   • Release Throttle Braking: Deceleration occurs when the throttle is released.
   • Brake Switch Braking: Activates deceleration based on a dedicated brake switch.
   • Reversing Braking / Neutral Braking: Specific braking behaviors when reversing or in neutral.
   Brake time and release time are configurable, and regenerative braking (regen) amount can be programmed for different modes.
5. Electronic Reversing: Utilize the reversing switch input for electronic direction changes. Configurable reversing acceleration function ensures smooth transitions.
6. High Pedal Protection: For safety, the controller will not operate if a high throttle input is detected during power-on. Ensure the throttle is in a neutral position before starting.

Maintenance

To ensure the longevity and reliable performance of your Kelly Jaguar series motor controller, consider the following maintenance points:

• Regular Inspection: Periodically check all wiring connections for tightness and signs of wear or corrosion.
• Cleanliness: Although the controller is IP66 rated waterproof, keeping the exterior clean from excessive dirt and debris is recommended. Avoid using high-pressure water jets directly on connectors.
• Heat Dissipation: Ensure that the controller's heatsink fins are free from obstructions to allow for efficient heat dissipation. For models requiring an external conductive heat sink, verify proper contact and thermal conductivity.
• Software Updates: Check the Kelly Controls website periodically for any available software or firmware updates for your controller model.

Troubleshooting

The Kelly Jaguar series motor controllers are equipped with extended fault detection and protection mechanisms. If you encounter an issue, the controller will provide diagnostic feedback:

• Fault Indication: The controller will emit a beep sound pattern to indicate the fault source. Additionally, error codes or messages can be read using the PC software or Android application.
• Battery Voltage Issues: The controller monitors battery voltage. It will cease operation if the voltage is too high and will progressively reduce motor power as battery voltage drops, eventually cutting out at the preset 'Low Battery Voltage' threshold.
• Overcurrent Protection: Built-in current loops and hardware overcurrent protection prevent damage from excessive current draw.
• Temperature Protection: The controller features configurable motor temperature protection. Current is reduced if the case temperature reaches 90℃ and shuts down at 100℃ to prevent overheating.
• Regenerative Braking Voltage: During regenerative braking, the controller monitors battery recharging voltage, cutting back current if voltage rises too high and stopping regen if it exceeds safe limits.
• Hardware Protection: The controller includes hardware-level overcurrent and overvoltage protection for critical components.

For detailed error code explanations and advanced troubleshooting, refer to the comprehensive user manual available on the Kelly Controls website or consult the programming software.

User Tips

No specific user tips were available from customer reviews or Q&A for this product at this time. Always refer to the official documentation and consider consulting with experienced professionals for complex installations or configurations.

Warranty and Support

For warranty information, technical support, or service inquiries, please contact the manufacturer or your authorized dealer. Ensure you have your product model and serial number available when seeking support.