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Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User

’s Manual

V 1.10

7

Figure1:

KHS controller Mounting Holes

‟ Dimensions (dimensions in millimeters)

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Summary of Contents for KHS32020II

Page 1: ...oltage Sine Wave Brushless DC Motor Controller User s Manual V 1 10 Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User s Manual Models KHS32020II KHS32020IIPS KHS36020II KHS36020IIPS Rev 1 10 July 2022 ...

Page 2: ... 6 Chapter 3 Wiring and Installation 6 3 1 Mounting the Controller 6 3 2 Connections 8 3 3 Installation Check List 15 Chapter 4 Programmable Parameters 16 4 1 Step 1 17 4 2 Step 2 21 4 3 Step 3 22 4 4 How to use Identification angle operation for KHS I controller 24 4 5 How to use Identification angle operation for KHS IPS controller 29 Chapter 5 Maintenance 36 5 1 Cleaning 36 5 2 Configuration 37...

Page 3: ...n 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 software is based on Tablet with Android OS Customers may add a Z TEK USB to RS232 cable for programming KHS controller if they want to use Android Tablet Both PC software and Android APP can provide one screen...

Page 4: ...e shutting down at 110 6 The controller keeps monitoring and battery recharging voltage during regen braking 7 Maximum reverse speed and forward speed can be configured between 20 and 100 respectively and separately 8 A 4pin connector to RS232 port and a Z TEK USB to RS232 cable allows for configuration programming and software upgrades using the tablet which must be based on Android OS now People...

Page 5: ...ion The regen is not a safe function Usually you may use the mechanical brake 2 2 Features 1 Intelligence with powerful microprocessor 2 Integrated pre charge circuit 3 Synchronous rectification ultra low drop fast SVPWM and FOC to achieve more efficiency 4 Electronic reversing 5 Voltage monitoring on 3 motor phases bus and power supply 6 Voltage monitoring on voltage source 12V and 5V 7 Current s...

Page 6: ...ers 24 Support motors with any number of poles 25 Up to 70 000 electric RPM standard Electric RPM mechanical RPM motor pole pairs Motor pole pairs Motor poles 2 2 3 Specifications Frequency of Operation 10 20KHz by default 10KHz Standby Battery Current 0 5mA 5V or 12V Sensor Supply Current total 40mA Controller supply voltage range PWR 10V to 30V for pin7 and pin6 which must be isolated from main ...

Page 7: ...S320201I 190 A 200A 80A 90A 18V 380V KHS320201IPS 190 A 200A 80A 90A 18V 380V KHS360201I 190 A 200A 80A 90A 18V 450V KHS360201IPS 190 A 200A 80A 90A 18V 450V Note Continuous current was calculated based on controller with liquid cooling bottom plate Chapter 3 Wiring and Installation 3 1 Mounting the Controller The KHS controller can be oriented in any position which should be as clean and dry as p...

Page 8: ...Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User s Manual V 1 10 7 Figure1 KHS controller Mounting Holes Dimensions dimensions in millimeters ...

Page 9: ... 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 inactivated automatically Both Boost and Brake variable regen mode can not be used at the same time Figure 3 Waterproof Connector DJ7091Y 2 3 11 Pin Definition 14 REV_SW Reverse switch input Orange 6 RTN Signal return or power supply return Black 12 FWD...

Page 10: ...s Sine signal input on KHS IPS 17 Hall B Hall phase B Dark Green This is Cosine signal input on KHS IPS 16 Hall C Hall phase C Dark Blue There is no hall C signal input on KHS IPS Notes 1 All RTN pins are internally connected 2 Meter function is to copy either of hall sensors 3 Switch to 12V is active Open switch is inactive Caution Do not apply power until you are certain the controller wiring is...

Page 11: ...lly KHS High Voltage Sine Wave Brushless DC Motor Controller User s Manual V 1 10 10 3 2 2 Simple Wiring of the Controller s Auto Identification Figure 4 KHS I Controller Simple Wiring Auto Identification ...

Page 12: ...Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User s Manual V 1 10 11 Figure 5 KHS IPS Controller Simple Wiring Auto Identification ...

Page 13: ...igh Voltage Sine Wave Brushless DC Motor Controller User s Manual V 1 10 12 3 2 3 Standard Wiring of the Controller Figure 6 KHS I Controller Standard Wiring FNR Figure 7 KHS I Controller Standard Wiring 3 speeds ...

Page 14: ...Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User s Manual V 1 10 13 Figure 8 KHS IPS Controller Standard Wiring FNR Figure 9 KHS IPS Controller Standard Wiring 3 speeds ...

Page 15: ... of the pin supplies the second braking function of the 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 I controller on pin11 Figure 12 Wiring diagram for motor temperature sensor NOTE KHS controller can support KTY84 150 KTY84 130 KTY83 122 thermistors ...

Page 16: ...r 3 3 Installation Check List Before operating the vehicle 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 Do not allow anyone to stand directly in front of or behind the vehicle during the checkout Make sure the PWR switch and the brake is off Use wel...

Page 17: ...ogrammable Parameters KHS Configuration program allow users to set parameters according to the vehicle actual working environment so as 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 on PC software or Android App The Android Tablet is preferred Fi...

Page 18: ...al description Set max battery current so as to protect battery A lower value means a lower battery output current and better protective effect But excessively low value will affect acceleration Suggestion Factory default is 100 5 Identification Angle Please download the instruction to how to use Identification angle function from the website www kellycontroller com support php If you can read 85 ...

Page 19: ...ve 4 5V or below 4 5V Usually the hall output voltage is 4 2V Max If you adjust it to lower value which is near 4 2V it may trigger the error code in normal way 8 TPS Type TPS Type 1 0 5V 3 wire 0 5K pot 5K is normal 2K 20K can be used 2 Hall active throttle or pedal Range 1 2 9 TPS Dead Low TPS Dead Zone Low Range 5 40 Functional description Set throttle effective starting point Suggestion Set ac...

Page 20: ...in22 and pin12 are disconnected from pin11 the controller is driving with medium speed mode Three speed This item is used to enable or disable three speed function By default it is at 0 0 Three speed function is disabled 1 Two speed function 2 Three speed function is enabled 18 PWM Frequency Frequency of PWM operation Unit KHz Functional description 20KHz is better for hub motor with strict quiet ...

Page 21: ...tuation factory default is Disable 20 B Foot Switch Value range Enable and Disable Functional description If enabled the foot switch will be activated The controller will not accept the throttle signal if the foot switch is turned off Please see figure 4 1 Suggestion Set according to the practical situation factory default is Disable Configuration Pin Status Running Status Forward Switch Foot Swit...

Page 22: ...ctory default is Disable 26 Anti Slip If enabled the controller will try to prevent the vehicle rolling back on downhill faster and faster If the ratio of gearbox is high it can try to help the motor stop on the downhill But usually this function only helps motor stop rolling back too fast Suggestion factory default is Disable 27 Change Direction If the direction is not what you expected after fin...

Page 23: ...speed sensor supplier provided sensors with 2 5V or 3 0V zero crossing point You can change it back between 2 5V and 3 0V if the motor can not run Suggestion Set according to the practical situation factory default is 613 3 0V for Mars 1114 1115 1302 1304 from Motenergy company Value Range 0 1023 maps 0 5V 7 Line Hall Amplitude The position signal based on Zero crossing point It is only useful whe...

Page 24: ...ake Time the time of Brake Torque from 0 to max accuracy 0 1s Range 1 250 Factory set is 15 6 Brake Rls Time Brake Release Time the time of Brake Torque from max to 0 accuracy 0 1s Range 1 250 Factory 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 re...

Page 25: ...ernal calculation for MCU 246 is about 11 degrees in environment 4 4 How to use Identification angle operation for KHS I controller We must do Identification angle operation before running motor for all KHS controllers The Identification angle operation can be done in PC program or Android App Tablet or Cell Phone KHS I controller is designed for BLDC motor with three hall sensors By default the s...

Page 26: ...Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User s Manual V 1 10 25 2 Please connect the controller to user program by using an USB to RS232 cable and SM 4A DB9 RS232 Converter ...

Page 27: ... 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 Please download the controller user program from our website for free https kellycontroller com support Please install the user program in your computer Tablet or Phone 4 Please turn on the key switch so tha...

Page 28: ...e 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 power supply after the power supply is off for a few seconds The motor shaft will try to run on directions randomly It is normal because the controller is doing Identification angle operation 7 Please wait abo...

Page 29: ...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 not write it back to 85 by manual Please wait longer time until the error codes occur Please don t keep 170 in the identification angle item when you want to turn off the power supply Otherwise the controller ...

Page 30: ...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 IPS controller 1 Please hook up the controller for identification angle operation according to the wiring diagram below Please make sure there is no load on the motor shaft before starting the programming The KHS IPS is designed by opto isolated technology We specify 10 30V for...

Page 31: ...Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User s Manual V 1 10 30 2 Please connect the controller to user program by using an USB to RS232 cable and SM 4A DB9 RS232 Converter ...

Page 32: ... 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 DB9 RS232 converter any more when you use Bluetooth converter for programming the controller 3 Please download the controller user program from our website for free ...

Page 33: ...lick 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 item is at 85 4 2 Because this is a KHS IPS controller based on Sin Cosin speed sensor We need to configure the correct parameters for Sin Cosin speed sensor settings Most of PMSM motor with Sin Cosin speed s...

Page 34: ...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 in the user program Line hall amplitude The document showed the Amplitude is 1 1V 0 2V We think the amplitude is 1 1V for now So we need to fill 1 1 1023 5 225 for line hall amplitude instead of 410 in the u...

Page 35: ...s 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 angle operation We may wait a few seconds to reset the power supply after change the settings 5 Please fill 170 in the identification angle item And please click the write button The user program will give a po...

Page 36: ...n 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 angle operation again You just need to enable Change Direction item in the first picture of user program Please click Write Button and reset the power supply to activate the setting Then the motor will run on ...

Page 37: ...reviously 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 cleaning of the controller should be carried out The controller is a high powered device When working with any battery powered vehicle proper safety precautions should be taken that include but are not limited to ...

Page 38: ...fore 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 power supply return supply negative to any RTN pin KHS controller requires a 4pin connector to Kelly RS232 Converter to support the communication And customers may need a Z TEK USB cable for Tablet with Andro...

Page 39: ...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 thr...

Page 40: ...entification 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 Motor temperature is higher than the configured maximum The controller will shut down until the motor temperature cools down 4 4 Hall Galvanometer sensor error 1 Hall galvanometer device is damaged inside the...

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