Kelly KHS Series User Manual Download Page 41

Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 

                                                                     

 

40

 

 

Table 1: ERROR CODES 

LED Error Codes 

 

ode

 

Explanation

 

Solution 

1,1 

¤        ¤

 

Automatic error 

identification 

1.  Wrong wiring of motor phase line or hall. 

Please suspend the motor when enable 
Auto-Identify function. 

1,2 

¤        ¤¤

 

Over voltage error

  2.  Battery voltage is too high for the controller. 

Check battery volts and configuration. 

3.  Regeneration over-voltage. Controller will have 

cut back or stopped regen. 

4.  This only accurate to ± 2% upon Overvoltage 

setting. 

1,3 

¤        ¤¤¤

 

Low voltage error

  1.  The controller will clear after 5 seconds if battery 

volts returns to normal. 

2.  Check battery volts & recharge if required. 

1,4 

¤        ¤¤¤¤

  Reserved 

 

2,1 

¤¤      ¤

 

Motor did not start

  Motor did not reach 25 electrical RPM within 2 

seconds of start-up. Hall sensor or phase wiring 
problem. 

2,2 

¤¤      ¤¤

 

Internal volts fault

  1.  Measure that B+ & PWR are correct when 

measured to B- or RTN.   

2.  There may be excessive load on the +5V supply 

caused by too low a value of Regen or throttle 
potentiometers or incorrect wiring. 

3.  Controller is damaged. Contact Kelly about a 

warranty repair. 

2,3 

¤¤      ¤¤¤

 

Over temperature 

  The controller temperature has exceeded 100

. The 

controller will be stopped but will restart when 
temperature falls below 80

2,4 

¤¤      ¤¤¤¤

 

Throttle error at 

power-up 

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

Summary of Contents for KHS Series

Page 1: ...25 Kelly KHS High Voltage Opto Isolated Sinusoidal Motor Controllers User s Manual Devices Supported KHS32020I KHS32020IPS KHS32030N KHS32030NPS KHS32035N KHS32035NPS KHS32040N KHS32040NPS KHS36020I...

Page 2: ...lation 6 Chapter 3 Wiring and Installation 6 3 1 Mounting the Controller 6 3 2 Connections 9 3 3 Installation Check List 17 Chapter 4 Programmable Parameters 18 4 1 Step 1 18 4 2 Step 2 23 4 3 Step 3...

Page 3: ...btain diagnostic information quickly and easily People can program the KHS controller on PC software and Android App There is one more choice for customers to program KHS controller now The APP softwa...

Page 4: ...ontroller The current begins to ramp down at 90 case temperature shutting down at 110 6 The controller keeps monitoring and battery recharging voltage during regen braking 7 Maximum reverse speed and...

Page 5: ...chased in addition from our website This small converter is only useful for KHS controller 22 Can support three speed function on the latest version Caution The regen is not a safe function Usually yo...

Page 6: ...ing the controller to App program in Tablet 23 User program provided Easy to use No cost to customers 24 Support motors with any number of poles 25 Up to 70 000 electric RPM standard Electric RPM mech...

Page 7: ...200 80 KHS32030N NPS 18 380 300 150 KHS32035N NPS 18 380 350 175 KHS32040N NPS 18 380 400 200 KHS36020I IPS 18 450 200 80 KHS36025N NPS 18 450 250 125 KHS36030N NPS 18 450 300 150 KHS36035N NPS 18 450...

Page 8: ...Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User s Manual V 1 25 7 Figure1 KHS I series mounting holes dimensions dimensions in millimeters...

Page 9: ...Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User s Manual V 1 25 8 Figure 2 KHS N series mounting holes dimensions dimensions in millimeters B B U V W M8...

Page 10: ...regeneration mode used the same pin as pin2 When Boost is disabled in the user program the pin2 can be used as brake variable regen mode When Boost is enabled the brake analog regen mode is inactivat...

Page 11: ...all phase A Yellow This is Sine signal input on KHS IPS 17 Hall B Hall phase B Dark Green This is Cosine signal input on KHS NPS 16 Hall C Hall phase C Dark Blue There is no hall C signal input on KHS...

Page 12: ...Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User s Manual V 1 25 11...

Page 13: ...igh Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User s Manual V 1 25 12 3 2 2 Simple Wiring of the Controller s Auto Identification Figure 4 KHS I Controller Simple Wiring Auto Iden...

Page 14: ...Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User s Manual V 1 25 13 Figure 5 KHS NPS Controller Simple Wiring Auto Identification...

Page 15: ...age Sinusoidal Brushless Permanent Magnet Motor Controller User s Manual V 1 25 14 3 2 3 Standard Wiring of the Controller Figure 6 KHS N Controller Standard Wiring FNR Figure 7 KHS N Controller Stand...

Page 16: ...elly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User s Manual V 1 25 15 Figure 8 KHS NPS Controller Standard Wiring FNR Figure 9 KHS NPS Controller Standard Wiring 3 speed...

Page 17: ...e controller Figure 10 Wiring of brake switch 12V 12V is provided by external source Figure 11 Wiring of brake switch 12V 12V is provided by KHS N controller on pin11 Figure 12 Wiring diagram for moto...

Page 18: ...cle complete the following checkout procedure Use LED 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...

Page 19: ...to be at its best The default parameters of the controller are not recommended for all applications Make sure set the proper parameters before making any test to avoid danger Customers can do program...

Page 20: ...troller com support php If you can read 85 in Identification Angle item that is to say the system is stable and normal Please fill in 170 for Identification Angle item in user program Then please clic...

Page 21: ...effective starting point Suggestion Set according to the practical situation factory default is 20 5V 1 0V 10 TPS Dead High TPS Dead Zone High Range 60 95 Functional description Set throttle effectiv...

Page 22: ...al description 20KHz is better for hub motor with strict quiet control Suggestion Set according to the practical situation factory default is 20KHz Please don t set it 20KHz above Value Range 10KHz or...

Page 23: ...Disable OFF OFF x Neutral OFF ON x Reverse ON OFF x Forward ON ON x Neutral Disable Enable x OFF OFF Can t operate x ON OFF Can t operate x ON ON Reverse x OFF ON Forward Disable Disable x OFF x Forw...

Page 24: ...just choose Change Direction item Please click Write button to activate Change Direction function The motor direction will be what you expected after the power supply is reset Suggestion factory defau...

Page 25: ...plitude The position signal based on Zero crossing point It is only useful when the speed sensor is at 4 For example if the Line hall Amplitude is 1 1V the signal output of Sine Cosine sensors is from...

Page 26: ...y 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 regen mode You have to turn on the brake switch after the throttle is released for the r...

Page 27: ...use Identification angle operation for KHS N controller We must do Identification angle operation before running motor for all KHS controllers The Identification angle operation can be done in PC pro...

Page 28: ...KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User s Manual V 1 25 27 2 Please connect the controller to user program by using an USB to RS232 cable and SM 4A DB9 RS232 Conv...

Page 29: ...an buy our Bluetooth converter to connect the controller to Android Phone We don t have to use SM 4A to DB9 RS232 converter any more when you use Bluetooth converter for programming the controller 3 P...

Page 30: ...lick the write button The user program will give a pop up window which show the Write operation is successful Please quit from the user program Please turn off the power supply 6 Please turn on the po...

Page 31: ...error codes such as Identify error hall err etc please return to the first picture of user program Please write 85 instead in identification angle by manual If there are no any error codes you can no...

Page 32: ...d for BLDC or PMSM motor with Sin Cosin sensors By default the speed sensor type is set at 4 from factory setting for KHS NPS controller 1 Please hook up the controller for identification angle operat...

Page 33: ...KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User s Manual V 1 25 32 2 Please connect the controller to user program by using an USB to RS232 cable and SM 4A DB9 RS232 Conv...

Page 34: ...9 RS232 Converter to connect the controller to an Android Tablet The third option is customers can buy our Bluetooth converter to connect the controller to Android Phone We don t have to use SM 4A to...

Page 35: ...ry to click Read button in user program or App You will see the first picture of user program Please check whether the Identification Angle item is at 85 or not It is correct if identification angle i...

Page 36: ...ensor Please click Motor button in the user program Line hall zero The line hall zero point is at 3Vdd 5 3 5V 5 3 0V So we need to fill 3 1023 5 613 8 614 for Line hall zero parameter instead of 508 i...

Page 37: ...settings And we need to do identification angle operation each time after you changed the settings We need to reset the power supply each time when we change the settings and do the identification ang...

Page 38: ...ication angle item before power supply is turned on after the identification operation is successful 15 If the direction of the motor is not what you expected please don t try to do Identification ang...

Page 39: ...t up previously Chapter 5 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 cleanin...

Page 40: ...odes before Identification angle operation Use a straight through RS232 cable or USB converter provided by Kelly to connect to a host computer Provide 18V to PWR for a 24V controller provide 8V Wire p...

Page 41: ...after 5 seconds if battery volts returns to normal 2 Check battery volts recharge if required 1 4 Reserved 2 1 Motor did not start Motor did not reach 25 electrical RPM within 2 seconds of start up Ha...

Page 42: ...use Identification function instruction from our website 2 Incorrect wiring 3 Speed sensor is damaged or defective Or feedback signal is erratic 4 1 Reserved 4 2 Reserved 4 3 Motor over temperature Mo...

Reviews: