1. Introduction
This manual provides essential information for the safe and efficient operation of your Kelly KVD Series High-Power Brushless Motor Controller. The KVD series controllers are designed for use in electric three-wheeled and four-wheeled vehicles, offering precise control for brushless motors. Please read this manual thoroughly before installation and use to ensure proper functionality and safety.
2. Safety Information
WARNING: Electrical components can cause serious injury or death if not handled properly. Always disconnect power before performing any installation, maintenance, or troubleshooting procedures.
- Ensure all wiring connections are secure and correctly polarized.
- Avoid short circuits.
- Do not operate the controller in wet conditions or expose it to excessive moisture.
- Mount the controller in a location with adequate ventilation to prevent overheating.
- Only qualified personnel should perform installation and maintenance.
3. Specifications
The Kelly KVD series controllers are high-power brushless motor controllers. Specific parameters vary by model:
| Feature | KVD7215N | KVD7222N | KVD7230N |
|---|---|---|---|
| Nominal Voltage | 72V | 72V | 72V |
| Rated Current | 150A | 220A | 300A |
| DIY Supplies Category | Electrical | ||
| Origin | Mainland China | ||
| Certification | None | ||
Note: The image shows a fuse rated at 240A and a voltage range of 24-60V, which may apply to specific variants or general component ratings. The model numbers KVD72xxN typically indicate a 72V system.
4. Package Contents
Upon receiving your Kelly KVD Series Controller, please verify that the following items are included:
- Kelly KVD Series Brushless Motor Controller (selected model)
- Wiring Harness (pre-attached or separate, as applicable)
- Mounting hardware (screws, washers - may vary)
- User Manual (this document)
If any items are missing or damaged, please contact your supplier immediately.
5. Setup and Installation
5.1 Mounting the Controller
The controller features a robust heat sink design for efficient thermal management. Mount the controller securely to a flat, stable surface in a location that allows for adequate airflow. Use the provided mounting holes and hardware. Ensure the heat sink fins are not obstructed.
5.2 Wiring Connections
Refer to the diagram below for typical wiring connections. Always ensure power is disconnected before making any connections. The controller features clearly labeled terminals for main power, motor phases, and signal wires.
Key terminals and their functions:
- B+ (Red): Positive battery connection. Connect to the positive terminal of your vehicle's battery pack.
- B- (Black): Negative battery connection. Connect to the negative terminal of your vehicle's battery pack.
- M (Yellow, Blue, Green): Motor phase connections. These connect to the three phase wires of your brushless motor. Ensure correct phase sequence for proper motor rotation.
- P (Blue): Parking brake or other auxiliary input.
- NT (Green): Neutral or other auxiliary input.
- Fuse (240A shown): Integrated fuse for overcurrent protection. Ensure the fuse rating matches your system requirements.
- Signal Harness: Multi-pin connector for throttle input, ignition, reverse, speed sensor, and other control signals. Refer to the detailed wiring diagram specific to your vehicle's setup for precise connections.
It is highly recommended to consult a professional electrician or refer to a detailed wiring diagram provided by your vehicle manufacturer for specific connection instructions.
6. Operating Instructions
Once the controller is correctly installed and wired, follow these general steps for operation:
- Pre-Operation Check: Before applying power, double-check all wiring connections for tightness and correct polarity. Ensure no loose wires or potential short circuits.
- Power On: Turn on the vehicle's main power switch. The controller should initialize.
- Throttle Control: Gradually apply the throttle. The motor should respond smoothly. If the motor does not respond or behaves erratically, immediately power off and check connections and troubleshooting section.
- Direction Control: Use the vehicle's forward/reverse switch (if applicable) to change motor direction.
- Monitoring: Pay attention to any unusual noises, smells, or excessive heat from the controller or motor during operation.
- Power Off: Always turn off the main power switch when the vehicle is not in use.
7. Maintenance
Regular maintenance helps ensure the longevity and reliable performance of your Kelly KVD controller:
- Visual Inspection: Periodically inspect the controller for any signs of physical damage, corrosion, or loose connections.
- Cleaning: Keep the controller clean and free from dust, dirt, and debris. Use a soft, dry cloth. Do not use solvents or abrasive cleaners.
- Connection Checks: Ensure all power and signal connections remain tight and secure. Loose connections can lead to poor performance or damage.
- Thermal Management: Verify that the heat sink fins are clear of obstructions and that there is adequate airflow around the controller to prevent overheating.
- Fuse Inspection: Check the fuse periodically for signs of damage or degradation. Replace with a fuse of the correct rating if necessary.
8. Troubleshooting
If you encounter issues with your Kelly KVD controller, refer to the following common problems and solutions:
| Problem | Possible Cause | Solution |
|---|---|---|
| Motor does not run | No power to controller; Blown fuse; Loose connections; Faulty motor; Incorrect wiring. | Check battery voltage and main power switch; Inspect and replace fuse if blown; Verify all connections are secure; Test motor independently; Recheck wiring against diagram. |
| Motor runs erratically or with reduced power | Low battery voltage; Loose motor phase connections; Hall sensor issues; Overheating. | Charge battery; Check motor phase connections; Inspect Hall sensor wiring; Ensure adequate cooling. |
| Controller gets excessively hot | Insufficient ventilation; Overload condition; Faulty motor. | Improve airflow around controller; Reduce load on motor; Inspect motor for damage. |
| No response from throttle | Throttle wiring issue; Faulty throttle; Controller in error mode. | Check throttle connections; Test throttle output; Power cycle controller. |
If problems persist after attempting these solutions, contact technical support.
9. User Tips
- For optimal performance, ensure your battery pack is fully charged and in good condition.
- Always use appropriate gauge wiring for high-current connections to prevent voltage drop and overheating.
- Consider adding an external voltmeter to monitor battery voltage during operation.
10. Warranty and Support
For warranty information and technical support, please refer to the documentation provided at the time of purchase or contact your vendor. Keep your purchase receipt as proof of purchase.
