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Kelly KLS-M/N Brushless Motor Controller User’s Manual

V 2.5

26

2,Please connect the controller to user program by using an USB to RS232 cable and SM-4A
DB9(RS232) Converter.

Customers also can use a Z-TEK USB 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

Summary of Contents for KLS Series

Page 1: ...KLS M N Brushless Motor Controller User s Manual V2 5 Kelly KLS M N Brushless Motor Controller User s Manual Devices Supported KLS7212M KLS7218M KLS7212N KLS7222N KLS6030N KLS7230N KLS7245N KLS7250N KLS6018N ...

Page 2: ...Kelly KLS M N Brushless Motor Controller User s Manual V 2 5 Rev 2 6 May 2018 ...

Page 3: ......

Page 4: ... 3 Specifications 5 2 4 Name Regulation 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 17 4 1 Step 1 17 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: ...igh 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 prog...

Page 6: ...ection 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 if ...

Page 7: ...igh 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 d...

Page 8: ...n of Kelly BLDC motor controllers KLS 72 18M 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 M The motor controller included a plastic cover And KLS M N is IP66 rating without filling the silica gel by default KLS M N used cast aluminum box as b...

Page 9: ...nd 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 airflow are vital to achieve the full power capability of the controller The case outline and mounting holes dimensions are sho...

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

Page 11: ...Kelly KLS M N Brushless Motor Controller User s Manual V 2 5 8 Figure 3 KLS6018N KLS7222N mounting holes dimensions dimensions in millimeters ...

Page 12: ...Kelly KLS M N Brushless Motor Controller User s Manual V 2 5 9 Figure 4 KLSxx30N mounting holes dimensions dimensions in millimeters ...

Page 13: ...Kelly KLS M N Brushless Motor Controller User s Manual V 2 5 10 Figure 5 KLS7245N mounting holes dimensions dimensions in millimeters ...

Page 14: ...Kelly KLS M N Brushless Motor Controller User s Manual V 2 5 11 Figure 6 KLS7250N mounting holes dimensions dimensions in millimeters 3 2 Connections 3 2 1 Pin definition of KLS M N Controller ...

Page 15: ...ake analog regen use the same port on pin2 4 CAN bus is not included in KLS M 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 ...

Page 16: ...ddle 5 5V 5V supply output 40mA Purple 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 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 Ca...

Page 17: ...ess Motor Controller User s Manual V 2 5 14 3 2 2 Standard Wiring of KLS M Controller Figure 6 KLS N M controller standard wiring Battery voltage can be used for controller supply 3 2 3 Optional wiring of KLS M controller ...

Page 18: ...h 12V 12V is provided by external source Figure 8 Wiring of brake switch 12V 12V is provided by KLS N controller on pin11 Figure 9 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 ...

Page 19: ...efore 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 behind the vehicle during the checkout Make sure the PWR switch and the brake is off Use well insulated tools Make sure ...

Page 20: ...e 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 prefered First of all people need to do Identification angle function for KLS controller before running the motor The controller needs to be connected to batteries moto...

Page 21: ...from the website www kellycontroller 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 click Write button in user program Please wait a few seconds before restart the power supply You will see some info on Monitor screen after power supply is reset If you see Re...

Page 22: ...tion factory default is 20 5V 1 0V 10 TPS Dead High TPS Dead Zone High Range 60 95 Functional description Set throttle effective ending point Suggestion Set according to the practical situation factory default is 80 5V 4 0V 11 Brake sensor type Brake sensor type for brake variable regen mode 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 12 Brake s...

Page 23: ...10KHz or 20KHz 19 Start up H Pedal Value range Enable and Disable Functional description If enabled the controller will detect the current pedal status at power up If throttle got effective output the controller will 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 D...

Page 24: ...tory default is Disable 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 th...

Page 25: ...l make the Cruise control quit Suggestion factory default is Disable 27 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 28 Change Direction If the ...

Page 26: ... It is only useful when the speed sensor is at 4 Useless 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 o...

Page 27: ...stment 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 direction of moto...

Page 28: ...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 three hall se...

Page 29: ...r to user program by using an USB to RS232 cable and SM 4A DB9 RS232 Converter Customers also can use a Z TEK USB 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 ...

Page 30: ... item is at 85 But customers still need to run identification angle operation before driving 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...

Page 31: ...nd there are other 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 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 ...

Page 32: ...necting the battery Make sure 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...

Page 33: ...l the older version before updating Please try to use Identify function 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 ...

Page 34: ...e caused by some transient fault 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 u...

Page 35: ...roller User s Manual V 2 5 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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