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Kelly KLS-H Brushless Motor Controller

User’s Manual

V1.10

Kelly KLS-H Brushless Motor

Controller

User’s Manual

Devices Supported:

KLS6022H

KLS6030H

KLS7215H

KLS7218H

KLS7222H

KLS7230H

KLS7245H

KLS7250H

KLS7275H

KLS8415H

KLS8422H

KLS8430H

KLS72501-8080H

KLS72601-8080H

KLS72701-8080H

KLS96301-8080H

KLS96401-8080H

KLS96501-8080H

KLS96601-8080H

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Summary of Contents for KLS-H

Page 1: ... Brushless Motor Controller User s Manual Devices Supported KLS6022H KLS6030H KLS7215H KLS7218H KLS7222H KLS7230H KLS7245H KLS7250H KLS7275H KLS8415H KLS8422H KLS8430H KLS72501 8080H KLS72601 8080H KLS72701 8080H KLS96301 8080H KLS96401 8080H KLS96501 8080H KLS96601 8080H ...

Page 2: ...Kelly KLS H Brushless Motor Controller User s Manual V1 10 Rev 1 10 Jun 2017 ...

Page 3: ......

Page 4: ...egulation 5 Chapter 3 Wiring and Installation 6 3 1 Mounting the Controller 6 3 2 Connections 10 3 3 Installation Check List 14 Chapter 4 Programmable Parameters 15 4 1 Step 1 18 4 2 Step 2 20 4 3 Step 3 21 4 4 How to use Identification angle operation function 22 Chapter 5 Maintenance 26 5 1 Cleaning 27 5 2 Configuration 27 Table 1 ERROR CODES 28 Contact Us 30 ...

Page 5: ...g technology to reduce the operation noise and 1 3 switching loss which well meets the noise reduction and efficiency requirements in the application of DC brushless motor It uses high power MOSFET s and SVPWM and FOC 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 c...

Page 6: ...d switch and Boost switch 11 3 analog 0 5V inputs that default to throttle input Brake analog input and motor temperature input 12 Copy signal of one of hall sensors 13 Configurable boost switch Enables the maximum output power achievable if the switch is turned on The effect is the same as full throttle position even if you don t turn throttle at all 14 12V brake switch input used different port ...

Page 7: ... housing for maximum heat dissipation and harsh environment 14 Rugged high current terminals and rugged aviation connectors for small signal 15 Thermal protection current cut back warning and shutdown on high temperature 16 Controller can do auto_Identification angle for different degrees of hall sensors 17 Configurable high pedal protection the controller will not work if high throttle is detecte...

Page 8: ... to 100 MOSFET temperature Max Battery Current Configurable 2 4 Name Regulation The name regulation of Kelly BLDC motor controllers KLS 72 30H KLS Kelly BLDC motor controller based on sinusoidal waveform which is supposed to work with BLDC motor with three hall sensors All KLS controllers can do regen brake function by default 72 72V batteries H The motor controller included a plastic cover with a...

Page 9: ... 3 Wiring and Installation 3 1 Mounting the Controller The controller can be oriented in any position which should be as clean and dry as possible and if necessary shielded with a cover to protect it from water and contaminants To ensure full rated output power the controller should be fastened to a clean flat metal surface with four screws Applying silicon grease or some other thermal conductive ...

Page 10: ...7 Figure 1 KLS7215H KLS7218H KLS6022H KLS6030H KLS7230H mounting holes dimensions dimensions in millimeters ...

Page 11: ...8 Figure 2 KLS7245H mounting holes dimensions dimensions in millimeters ...

Page 12: ...9 Figure 3 KLS7250H mounting holes dimensions dimensions in millimeters ...

Page 13: ...10 Figure 4 KLS7275H mounting holes dimensions dimensions in millimeters ...

Page 14: ...11 Figure 5 KLS72xxx 8080H KLS96xxx 8080H mounting holes dimensions dimensions in millimeters ...

Page 15: ...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 6 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 Forward swi...

Page 16: ...18 Hall A Hall phase A Yellow 17 Hall B Hall phase B Dark Green 16 Hall C Hall phase C Dark Blue 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 correct and has been double checked Wiring faults will damage the controller Ensur...

Page 17: ...14 3 2 2 Standard Wiring of KLS HC Controller Figure 6 KLS H controller standard wiring Battery voltage can be used for controller supply ...

Page 18: ...on of the controller Figure 7 Wiring of brake switch 12V 12V is provided by external source Figure 8 Wiring of brake switch 12V 12V is provided by KLS D controller on pin11 Figure 9 Wiring diagram for motor temperature sensor NOTE The motor temperature sensor and brake switch used the different I O port on latest ...

Page 19: ...32 converter Figure 11 SM 4P connector for communication interface on KLS H controller 3 3 Installation Check List Before operating the vehicle complete the following checkout procedure Use buzzer 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 behi...

Page 20: ...od power Chapter 4 Programmable Parameters KLS 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 T...

Page 21: ...attery Limit Current Limit the max value of Battery Current Range 20 100 Functional 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 ...

Page 22: ...st the high threshold voltage above 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...

Page 23: ...ll report fault and not operate Suggestion Set according to the practical situation factory default is Enable 20 Brake H Pedal Releasing Brake High Pedal Disable Value range Enable and Disable Functional description If enabled the controller will detect the current pedal status when release the brake If throttle got effective output the controller will report fault and not operate Suggestion Set a...

Page 24: ...able 20 A Three Gears Switch Value range Enable and Disable Functional description If enabled the Forward switch will be activated Please see figure 4 1 Suggestion Set according to the practical situation 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 i...

Page 25: ...e control The Cruise function can not be activated in reversing direction Release throttle and turn the throttle again or turn on the brake switch will make the Cruise control quit Suggestion factory default is Disable 27 Change Direction If the direction is not what you expected after finish the Identification angle operation please just choose Change Direction item Please click Write button to a...

Page 26: ...gears switch in user program The regen will happen when you turn F N R switch from Forward or backward to Neutral position Factory set is 0 3 Accel Time Accel Time the time of TPS Torque from 0 to max accuracy 0 1s 5 is equal to 0 5s Range 1 250 Factory set is 10 4 Accel Rls Time Accel Release Time the time of TPS Torque from max to 0 accuracy 0 1s Range 1 250 Factory set is 1 5 Brake Time Brake T...

Page 27: ...et swift direction changing by using joystick function you may enable Change Dir brake item in user program It will help the motor change the direction of motor quickly after you shift throttle from 0V to 5V or from 5V to 0V Suggestion factory default is Disable Note Thermistor is optional Default to KTY84 130 150 or KTY83 122 4 4 How to use Identification angle operation function We must do Ident...

Page 28: ...25 2 Please connect the controller to user program by using an USB to RS232 cable and SM 4A DB9 RS232 Converter ...

Page 29: ...ou use Bluetooth converter for programming the controller 3 Please download the controller user program from our website for free www kellycontroller com support php Please install the user program in your computer Tablet or Phone 4 Please turn on the key switch so that the controller can get power supply from B B and Pin7 Please try to open the user program in your computer or other devices Then ...

Page 30: ... 2 3 minutes 8 If the identification angle operation is finished the constant beep sound will be disappeared The beeper will beep an error code And you will see reset error message in the monitor screen of user program You can see the error message in monitor screen of user program for KLS D H controller also 9 Please turn off the power supply again Please wait about a few seconds to turn on the p...

Page 31: ...turn on power supply again When the error codes occur please quit from user program Please try again from step 6 14 Please don t keep 170 in identification 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 Di...

Page 32: ... much extra job for you please make sure the motor must be stopped before programming The controller may display fault code but it doesn t affect programming or configuration But it will affect the Identification angle operation Please try to eliminate the error codes before Identification angle operation Use a straight through RS232 cable or USB converter provided by Kelly to connect to a host co...

Page 33: ...rge 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...

Page 34: ...hrottle is repaired a restart will clear the fault 3 4 Angle sensor error 1 Speed sensor type error customers may set the correct sensor type through user program or App Please download how to 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 Motor tem...

Page 35: ...32 For more Information contact Frikkie Combrink 27 73 070 8545 sales zmsa co za Jo Smith 27 82 552 3917 jo zmsa co za 27 11 240 6900 info zmsa co za www zmsa co za ...

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