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Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User

’s Manual

V2.9

10

Figure 5: KLS4840N KLS7240N

mounting holes

’ dimensions

(dimensions in millimeters)

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Summary of Contents for KLS-N Series

Page 1: ...ess Permanent Magnet Motor Controller User s Manual Devices Supported KLS2412ND KLS2412N KLS2418N KLS4812ND KLS4812N KLS4818N KLS4830N KLS4840N KLS4850N KLS4875NC KLS48100NC KLS48120NC KLS7212ND KLS7212N KLS7215ND KLS7215N KLS7218N KLS7222N KLS7230N KLS7240N KLS7250N KLS7275NC KLS72100NC KLS72120NC Rev 2 9 Feb 2023 ...

Page 2: ... Features 4 2 3 Specifications 5 2 4 Name Regulation 5 Chapter 3 Wiring and Installation 6 3 1 Mounting the Controller 6 3 2 Connections 13 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 24 4 4 How to use Identification angle operation function 26 Chapter 5 Maintenance 31 5 1 Cleaning 31 5 2 Configuration 31 Table 1 Error Codes 32 Contact...

Page 3: ...r 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 conduct tests and obtain diagnostic information quickly and easily People can program the KLS controller on PC software and Android App There is one more choice for custom...

Page 4: ... hall sensors 10 5 switch inputs which are activated by connection to 12V Default to throttle switch brake switch reversing switch forward 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 ...

Page 5: ...n current cutback warning and shutdown at configurable high and low battery voltage 13 Aluminum based PCB board with heat sink plate on the bottom of controller 14 Waterproof 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 prote...

Page 6: ...k with BLDC motor with three hall sensors All KLS controllers can do regen brake function by default 24 24V batteries N The motor controller included a plastic cover And KLS N is IP66 rating without filling the silica gel by default KLS N used cast aluminum box as body protection D stands for conductive Kelly KLS N Sinusoidal Brushless Permanent Magnet Motor Controller Model Nominal Voltage Max Op...

Page 7: ...00A 200A KLS72100NC 48 72V 40 86V 600A 240A KLS72120NC 48 72V 40 86V 700A 280A Chapter 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 me...

Page 8: ...oller User s Manual V2 9 7 Figure 1 KLS2412ND KLS4812ND KLS7212ND KLS7215ND mounting holes dimensions dimensions in millimeters B B U V W M5 Bolts Figure 2 KLS2412N KLS4812N KLS7212N KLS7215N mounting holes dimensions dimensions in millimeters B B U V W M5 Bolts ...

Page 9: ...Kelly KLS N Sinusoidal Brushless Permanent Magnet Motor Controller User s Manual V2 9 8 Figure 3 KLS2418N KLS4818N KLS7218N KLS7222N mounting holes dimensions dimensions in millimeters ...

Page 10: ...Kelly KLS N Sinusoidal Brushless Permanent Magnet Motor Controller User s Manual V2 9 9 Figure 4 KLS4830N KLS7230N mounting holes dimensions dimensions in millimeters ...

Page 11: ...Kelly KLS N Sinusoidal Brushless Permanent Magnet Motor Controller User s Manual V2 9 10 Figure 5 KLS4840N KLS7240N mounting holes dimensions dimensions in millimeters ...

Page 12: ...Kelly KLS N Sinusoidal Brushless Permanent Magnet Motor Controller User s Manual V2 9 11 Figure 6 KLS4850N KLS7250N mounting holes dimensions dimensions in millimeters ...

Page 13: ...Sinusoidal Brushless Permanent Magnet Motor Controller User s Manual V2 9 12 Figure7 KLS4875NC KLS7275NC KLS48100NC KLS72100NC KLS48120NC KLS72120NC mounting holes dimensions dimensions in millimeters B B U V W M8 ...

Page 14: ... 4 CAN bus is not included in KLS N controller by default When boost is disabled in user program pin2 is used as brake analog regen mode When boost is enable pin2 is used for boost function You may not use two functions at the same time 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 switch or can be enabled as Hig...

Page 15: ...7 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 4 F N R control and three speed function can not be used at the same time They both used the same pin as pin12 FWD Caution Do not apply power until you are certain the controller wiring i...

Page 16: ...of KLS N Controller Figure 9 KLS N controller standard wiring Battery voltage can be used for controller supply 3 2 3 Optional wiring of KLS N controller The 12V input signal of the pin supplies the second braking function of the controller Figure 10 Wiring of brake switch 12V 12V is provided by external source ...

Page 17: ...ing diagram for motor temperature sensor NOTE KLS controller can support KTY84 130 150 and KTY83 122 thermistors 3 2 4 Communication Port A 4pin connector to RS232 port is provided to communicate with host computer for calibration and configuration Figure 13 RS232 Interface on 4pin connector to RS232 converter Figure 14 SM 4P connector for communication interface on KLS N controller ...

Page 18: ...he checkout Make sure the PWR switch and the brake is off Use well insulated tools Make sure the wire is connected correctly Turn the PWR switch on The fault code will be detected automatically at restart With the brake switch open select a direction and operate the throttle The motor should spin in the selected direction Verify wiring or voltage and the fuse if it does not The motor should run fa...

Page 19: ...in7 to batteries for Identification Angle operation Please download the instruction how to use Identification angle function from our website www kellycontroller com support php 4 1 Step 1 1 Low Volt The min voltage of reporting this fault Range 20 86 depending on model Controller will not operate when battery voltage is near the value so as to protect battery Suggestion Set according to the pract...

Page 20: ...ply again Then everything will be fine The motor is ready to be drived by the KLS controller Range 85 or 170 nothing else 6 TPS Low Err Hall active pedal if lower than the value report the fault of TPS Type Range 0 20 7 TPS High Err Hall active pedal if higher than the value report the fault of TPS Type Range 80 100 As you may know the output of hall throttle from Kelly is about from 0 86V to 4 2V...

Page 21: ...igh Range 60 95 Functional description Set throttle effective ending point Suggestion Set according to the practical situation factory default is 80 5V 4 0V 14 Max output Fre Max output frequency Unit Hz Functional description It will affect the top speed of the motor Suggestion Set according to the practical situation factory default is 1000Hz Please don t set it 1000Hz above 15 Max Speed Max Spe...

Page 22: ...ective output the controller will report fault and not operate Suggestion Set according to the practical situation factory default is Disable 21 NTL H Pedal Neutral position High Pedal Disable Only useful when Three gears switch function is enabled If enable the controller will detect the current pedal position or signal When the switch is in neutral poistion If the throttle got effective output s...

Page 23: ...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 Switch FWD_SW 12 REV_SW 14 Foot 15 Enable 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 ...

Page 24: ...help the motor stop on the downhill But usually this function only helps motor stop rolling back too fast Suggestion factory default is Disable 28 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 activate Change Direction function The motor direction will be what you expe...

Page 25: ...eless for KLS N or KLS M model 4 3 Step 3 1 RLS_TPS Brk RLS TPS Braking Percent the percent of Releasing Pedal BRK in max braking Range 0 50 This is used to adjust the regen current of releasing throttle regen mode type The regen will happen as long as the throttle is released completely Factory set is 0 2 NTL Brk NTL Braking Percent the percent of Neutral Braking in max braking Range 0 50 Only us...

Page 26: ... for PID adjustment If you think the acceleration performance is very very strong please adjust them to a lower value respectively 10 Change Dir brake Value range Enable and Disable It is only useful when you Enable the joystick function If you want to get swift direction changing by using joystick function you may enable Change Dir brake item in user program It will help the motor change the dire...

Page 27: ...t is normal This item is only useful for internal calculation for MCU 246 is about 11 degrees in environment 4 4 How to use Identification angle operation function We must do Identification angle operation before running motor for all KLS controllers The Identification angle operation can be done in PC program or Android App Tablet or Cell Phone KLS N M controller is designed for BLDC motor with t...

Page 28: ...Kelly KLS N Sinusoidal Brushless Permanent Magnet Motor Controller User s Manual V2 9 27 2 Please connect the controller to user program by using an USB to RS232 cable and SM 4A DB9 RS232 Converter ...

Page 29: ...SB to RS232 cable and SM 4A DB9 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 DB9 RS232 converter any more when you use Bluetooth converter for programming the controller ...

Page 30: ...ng Because the 85 means this controller finished the identification angle operation with the motor in factory before shipment Your motor is different from the motor from controller supplier 5 Please fill 170 in the identification angle item And please click 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 Ple...

Page 31: ...r 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 controlle...

Page 32: ...re the connections to the bus bars if fitted are tight To avoid physically stressing the bus bars use two well insulated wrenches 5 2 Configuration You can configure the controller with a host computer through either an RS232 or USB port Disconnect motor wiring from controller for configuring existing parameters in the user program or Android APP If this operation is too much extra job for you ple...

Page 33: ...on for motor and hall sensors in the user program Table 1 Error Codes Buzzer Error Codes Code 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 Controlle...

Page 34: ...lt condition like a temporary over current momentarily high or low battery voltage This can happen during normal operation 3 3 Hall throttle is open or short circuit When the throttle 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 ins...

Page 35: ...net Motor Controller User s Manual V2 9 34 Contact Us Kelly Controls Home Page http www KellyController com Download user manual instructions and user program www kellycontroller com support php E mail Sales Kelly Controls com Phone 01 224 637 5092 ...

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