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Kelly KLS-N Brushless Motor Controller User’s Manual

V 2.7

7

Figure 2: KLS2415N, KLS7215N

mounting holes’ dimensions

(dimensions in millimeters)

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Summary of Contents for KLS-N

Page 1: ...ser s Manual V2 7 Kelly KLS N Brushless Motor Controller User s Manual Devices Supported Rev 2 7 DEC 2020 KLS2412N KLS2415N KLS2418N KLS2430N KLS2445N KLS2412NX KLS7212N KLS7215N KLS7218N KLS7212NX KLS6018N KLS6030N KLS7230N KLS7245N KLS7250N ...

Page 2: ...3 Specifications 5 2 4 Name Regulation 5 Chapter 3 Wiring and Installation 6 3 1 Mounting the Controller 6 3 2 Connections 11 3 3 Installation Check List 16 Chapter 4 Programmable Parameters 17 4 1 Step 1 17 4 2 Step 2 22 4 3 Step 3 23 4 4 How to use Identification angle operation function 24 Chapter 5 Maintenance 29 5 1 Cleaning 29 5 2 Configuration 29 Table 1 Error Codes 30 Contact Us 32 ...

Page 3: ... 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 customers to program...

Page 4: ...onnection 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 on The effect is the same as full throttle position even ...

Page 5: ...gh 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 protection the controller will not work if high throttle is de...

Page 6: ...le 2 4 Name Regulation The name regulation of Kelly BLDC motor controllers KLS 72 18N 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 N The motor controller included a plastic cover And KLS N is IP66 rating without filling the silica gel by defa...

Page 7: ... 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 material to contact surface will enhance thermal performance Proper heat sinking and air...

Page 8: ...Kelly KLS N Brushless Motor Controller User s Manual V 2 7 7 Figure 2 KLS2415N KLS7215N mounting holes dimensions dimensions in millimeters ...

Page 9: ...Kelly KLS N Brushless Motor Controller User s Manual V 2 7 8 Figure 3 KLS2418N KLS6018N KLS7218N mounting holes dimensions dimensions in millimeters ...

Page 10: ...Kelly KLS N Brushless Motor Controller User s Manual V 2 7 9 Figure 4 KLSxx30N mounting holes dimensions dimensions in millimeters ...

Page 11: ...Kelly KLS N Brushless Motor Controller User s Manual V 2 7 10 Figure 5 KLSxx45N mounting holes dimensions dimensions in millimeters ...

Page 12: ...Kelly KLS N Brushless Motor Controller User s Manual V 2 7 11 Figure 6 KLS7250N mounting holes dimensions dimensions in millimeters 3 2 Connections 3 2 1 Pin definition of KLS N NX Controller ...

Page 13: ...en 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 High speed switch function White 11 12V 12V Source Red 25 12V b...

Page 14: ... 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 is correct and has been double ch...

Page 15: ...roller Figure 8 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 9 Wiring of brake switch 12V 12V is provided by external source ...

Page 16: ...r on pin11 Figure 11 Wiring 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 12 RS232 Interface on 4pin connector to RS232 converter ...

Page 17: ...o 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 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 directi...

Page 18: ... motor and throttle before Identification operation That is to say it is not enough to connect only power supply PWR pin7 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 90 Controller will not operate wh...

Page 19: ...the power supply 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 ...

Page 20: ...he 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 Speed rpm Range 0 15000 By default it is set at 4000 Software version 0109 can support 15000RPM settings in...

Page 21: ...e 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 position If the throttle got effective output signal the controller will not operate and report fault code Suggestion Set according to the practical situation factory default is Disable 22 Joystick function If enable the controller can dr...

Page 22: ... 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 Forward x ON x Reverse Note X means can be on or off Figure 4 2 24 Boost If enabled the controller will output max power for a while Boost function is just full throttle position when you turn on boost switch even if the throttle is not operated at all The boost function is still based on limit...

Page 23: ...you expected after the power supply is reset Suggestion factory default is Disable 4 2 Step 2 1 Motor Nominal Curr When the controller is doing identification angle operation without load on the motor shaft there is a current requirement for identification operation If the motor rated power is very high please increase this parameter to a higher value Otherwise please keep it at 80 by default If t...

Page 24: ...tch 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 Time the t...

Page 25: ...tion is enabled in the user program When you want to use Change Dir Brake to reduce the delay time when you shift the direction under joystick operation there is a RPM limitation to use Change Dir Brake function which is only activated when the motor RPM is between IVT BRK MIN and IVT BRK MAX Suggestion factory default is Disable 13 Torque Speed Kp 3000 Torque Speed Ki 80 Speed Err Limit 1000 Thes...

Page 26: ...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 2 Please connect the controller to user program by using an USB to RS232 cable and SM 4A DB9 RS232 Converter ...

Page 27: ...able 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 28: ...cation 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 Please turn off the power supply 6 Please turn on the power supp...

Page 29: ... 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 will try to keep doing identification operation all the ti...

Page 30: ...tions 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 please make sure...

Page 31: ...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 Controller w...

Page 32: ...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 instru...

Page 33: ...oller User s Manual V 2 7 32 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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