Kelly KAC-N IP66 Rated Waterproof Jaguar Series AC Induction Motor Controller User Manual

1. Introduction

This manual provides essential information for the installation, operation, and maintenance of the Kelly KAC-N IP66 Rated Waterproof Jaguar Series AC Induction Motor Controller. The KAC-N series offers robust and efficient control for various AC induction motors, featuring advanced protection mechanisms and configurable parameters. Please read this manual thoroughly before attempting to install or operate the controller.

2. Specifications

2.1. Model-Specific Parameters

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

2.2. General 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

3. Features

• Intelligence with powerful microprocessor.
• Synchronous rectification, ultra low drop and fast SVPWM and FOC to achieve very high efficiency.
• Electronic reversing.
• Voltage monitoring on 3 motor phases, bus, and power supply.
• Voltage monitoring on voltage source 12V and 5V.
• Current sense on all 3 motor phases.
• Current control loop.
• Hardware over current protection.
• Hardware over voltage protection.
• Configurable limit for motor current and battery current.
• Low EMC.
• Battery protection: current cutback, warning and shutdown at configurable high and low battery voltage.
• Friendly high current terminals, and waterproof connectors for small signal.
• Thermal protection: current cut back, warning and shutdown at high temperature.
• Decelerating speed according to the brake rate when brake switch is active.
• Decelerating speed according to the brake rate at reverse. Configurable reversing accelerating function.
• Support three braking modes: release throttle braking, brake switch braking or reversing braking, neutral braking. Configurable brake time and brake release time in configuration program. Can program the regen amount in user program for different regen modes.
• Configurable high pedal protection: the controller will not work if high throttle is detected at power on.
• Current multiplication: Take less current from battery, output more current to motor.
• Easy installation: 3-wire potentiometer can work.
• Standard PC/Laptop computer to do programming. There is one more choice for customers to program 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 Tablet.
• User program provided. Easy to use. User program can be downloaded from our website for free.

4. Installation and Setup

Proper installation is crucial for the safe and efficient operation of your KAC-N controller. Ensure all connections are secure and correctly wired according to your system's requirements. While detailed wiring diagrams are typically provided with your specific motor and vehicle setup, general dimensions for various KAC-N models are provided below to assist with physical integration.

4.1. Physical Dimensions

4.2. Electrical Connections

The controller features friendly high current terminals for power connections and waterproof connectors for small signal wires. A 3-wire potentiometer can be used for throttle input. The controller provides +5V and +12V outputs for various sensors. Ensure all connections are made according to the specific wiring diagram for your application, typically found in the comprehensive user program documentation.

5. Operating Instructions

The KAC-N controller offers extensive configurability through its user program. This allows for precise control over motor operation, including speed, braking, and protection settings.

5.1. Basic Operation

• Throttle Input: Connect a 0-5V (3-wire resistive pot) or 1-4V (hall active throttle) to the designated analog input.
• Switch Inputs: The controller supports 3 switch inputs activated by connection to +12V, typically for forward, brake, and reversing functions.
• Speed Control: Maximum reverse and forward speeds are configurable between 20% and 100% independently.
• Braking Modes: The controller supports release throttle braking, brake switch braking, reversing braking, and neutral braking. Brake time and release time are configurable. Regenerative braking amount can also be programmed.

5.2. Configuration and Programming

The controller can be configured, programmed, and updated using a standard PC/Laptop or an Android OS tablet. A 4-pin connector to RS232 converter and a USB to RS232 cable are required for connection. The user program is available for free download from the manufacturer's website.

6. Maintenance

The KAC-N controller is designed for durability with an IP66 waterproof rating, offering protection against dust and powerful water jets. Regular maintenance should focus on:

• Visual Inspection: Periodically check for any signs of physical damage, loose connections, or corrosion on terminals.
• Cleaning: Keep the controller's exterior clean from excessive dirt or debris. Due to its IP66 rating, it can be gently wiped down or rinsed, but avoid high-pressure washing directly on connectors.
• Heat Dissipation: Ensure the heat sink fins are clear of obstructions to allow for proper cooling, especially if operating at higher continuous currents.

No user-serviceable parts are inside the sealed unit. Do not attempt to open the controller, as this may void any warranty and compromise its waterproof integrity.

7. Troubleshooting

The KAC-N controller features extended fault detection and protection mechanisms to help diagnose issues.

• Beep Codes: The controller emits a beep sound pattern to indicate specific fault sources. Refer to the detailed user program documentation for a list of these patterns and their corresponding error codes.
• Software Diagnostics: Error codes and messages can be read using the PC software or Android application when connected to the controller. This provides more detailed diagnostic information.
• Common Protections: The controller includes protections for over-current, over-voltage, low battery voltage, and motor/controller over-temperature. These protections will either cut back current, issue warnings, or shut down the system to prevent damage.

If an issue persists after consulting the software diagnostics and user program documentation, contact technical support.

8. User Tips

• Proper Wiring: Always double-check all wiring connections before applying power to prevent damage to the controller or other components.
• Initial Configuration: Take time to properly configure the controller using the PC software or Android app to match your motor and battery specifications for optimal performance and safety.
• Heat Management: For applications requiring high continuous current, ensure adequate heat sinking or airflow around the controller to prevent thermal cutbacks.
• Software Updates: Periodically check the manufacturer's website for software updates to ensure you have the latest features and bug fixes.

9. Warranty and Support

For specific warranty terms and conditions, please refer to the documentation provided at the time of purchase or contact your seller directly. Technical support and software downloads are typically available through the manufacturer's official channels.