Controller, Kelly 24-120V with REGEN

KDZ12401 is a 24-120 Volt (nominal input), 400A (peak output) programmable DC controller with optional regenerative braking.
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Programmable motor controllers provide efficient, smooth and quiet control for electric vehicles like go-carts, electric motorcycles, forklifts and hybrid vehicles, as well as electric boats and industrial motor speed control. It uses high power MOSFET’s and, fast PWM 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.

Caution! Regeneration has braking effect but does not replace the function of a mechanical brake. A mechanical brake is required to stop your vehicle. Regen IS NOT a safety feature! Controller may stop regen, without warning, to protect itself or the battery(it won’t protect you!).


Main Features and Specifications

General functions

  • Extended fault detection and protection. The LED flashing pattern indicates the fault sources.
  • 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.
  • 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 Ccase temperature, shutting down at 100 C.
  • 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.
  • Maximum reverse speed is configurable to half of the maximum forward speed.
  • Configurable and programmable with a host computer though RS232 or USB. Provide free GUI which can run on Windows XP/2000, Windows 7 and Vista(recommend using Kelly Standard USB To RS232 Converter).
  • Provision of a +5 volt output to supply various kinds of sensors, including Hall effect type.
  • Multifunctional and configurable 3 switch inputs: brake switch, reversing switch, throttle or forward switch. Active low.
  • 3 analog 0-5V inputs that default to throttle input, brake input and motor temperature input.
  • Pulsed reverse alarm output.
  • Maximum reverse power is configurable to half power.
  • Configurable motor over-temperature detection and protection with the recommended thermistor KTY84-130.
  • Optional 12V output power which can only be applied for Switch signals or LED. Any heavy load is inhibited.


•Intelligence with powerful microprocessor.

•Synchronous rectification, ultra low drop, and fast PWM to achieve very high efficiency.

•Voltage monitoring on voltage source 12V and 5V.

•Hardware over current protection.

•Hardware over voltage protection.

•Current limit and torque control.

•Low EMC.

•LED fault code.

•Battery protection: current cutback, warning and shutdown at configurable high and low battery voltage.

•Rugged aluminum housing for maximum heat dissipation and harsh environment.

•Rugged high current terminals, and rugged aviation connectors for small signal.

•Thermal protection: current cut back, warning and shutdown at high temperature.

•Configurable Current-Mode or Voltage-Mode when Field Switch is enabled, to achieve higher safety and reliability.

•Configurable high pedal protection: the controller will not work if high throttle is detected at power on.

•Brake switch is used to start regen.

•0-5V or 0-5K brake signal is used to command regen current.

•Capable of detecting short-circuit fault in the main contactor at power on.

•Easy installation: 1-4V "Hall Active" throttle, or 0-5K or 0-5V potentiometer(<100K) can work.

•Standard PC/Laptop computer is used to do programming. No special tools needed.

•User program provided. Easy to use. No cost to customers.


•Frequency of Operation: 16.6kHz.

•Standby Battery Current: < 0.5mA.

•Controller power supply current, PWR, <150mA.

•Configurable battery voltage range, B+. Max operating range: 8V to 136V

•Standard Throttle Input: 0-5K(2-wire resistive pot), 0-5V (3-wire resistive pot), 1-4V (hall active throttle).

•Analog Brake and Throttle Input: 0-5V or 0-5K.

•Reverse Alarm, Main Contactor Coil Driver, Meter.

•Full Power Temperature Range: 0 C to 50 C (controller case temperature).

•Operating Temperature Range: -30 C to 90 C , 100 C shutdown (controller case temperature).

•Motor Current Limit, 1 minutes: 200A-650A, depending on the model.

•Motor Current Limit, continuous:80A-260A, depending on the model.


For further detail, see KDZ Series/PM Controller documentation:
Download Kelly KDZ Controllers User Manual V3.3
Download Kelly KDZ User Configuration Program Setup V4.1
Kelly KDZ Controllers Configuration Program Online Demo/Help
Download Kelly KDZ Assembly Wiring Diagram V1.1