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Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User

’s Manual

V2.9

Kelly High-current series KLS-N

Sinusoidal Brushless Permanent Magnet Motor Controllers

User’s Manual

Devices Supported:

KLS4860NG

KLS7260NG

KLS4860NE

KLS7260NE

KLS4875NC

KLS7275NC

KLS48100NC KLS72100NC

KLS48120NC KLS72120NC

Rev. 2.9

Summary of Contents for KLS4860NE

Page 1: ...troller User s Manual V2 9 Kelly High current series KLS N Sinusoidal Brushless Permanent Magnet Motor Controllers User s Manual Devices Supported KLS4860NG KLS7260NG KLS4860NE KLS7260NE KLS4875NC KLS...

Page 2: ...Kelly KLS N Sinusoidal Brushless Permanent Magnet Motor Controller User s Manual V2 9 Feb 2023...

Page 3: ...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 9 3 3 Installation Check List 13 Chapter 4 Programmable Paramete...

Page 4: ...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...

Page 5: ...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 t...

Page 6: ...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 signa...

Page 7: ...2412ND 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 24 24V...

Page 8: ...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 t...

Page 9: ...inusoidal Brushless Permanent Magnet Motor Controller User s Manual V2 9 7 Figure 8 KLS4875NC KLS7275NC KLS48100NC KLS72100NC KLS48120NC KLS72120NC mounting holes dimensions dimensions in millimeters...

Page 10: ...ushless Permanent Magnet Motor Controller User s Manual V2 9 8 Figure 9 With Aluminum Liquid Cooling Heatsink at the bottom Only for 400A and above controllers mounting holes dimensions dimensions in...

Page 11: ...nal is valid to 12V 2 12V only can be used for LED or switch signals 3 Boost and brake analog regen use the same port on pin2 4 CAN bus is not included in KLS N controller by default When boost is dis...

Page 12: ...l return Black 1 Temp Motor temperature sensor input Raddle 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 A...

Page 13: ...nual V2 9 11 3 2 2 Standard Wiring of KLS N Controller Figure 11 KLS N controller standard wiring Battery voltage can be used for controller supply 3 2 3 Optional wiring of KLS N controller The 12V in...

Page 14: ...ke switch 12V 12V is provided by KLS N controller on pin11 Figure 14 Wiring diagram for motor temperature sensor NOTE KLS controller can support KTY84 130 150 and KTY83 122 thermistors 3 2 4 Communica...

Page 15: ...irectly 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 Th...

Page 16: ...efore 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 Identifi...

Page 17: ...Monitor screen that is to say the auto_Identification is finished You can see 85 in the Identification Angle item again And the controller will blink error code This is normal Please reset the power...

Page 18: ...can be used 2 Hall active throttle or pedal Range 1 2 12 Brake sensor Dead Low Brake sensor Dead Zone Low Range 5 40 Functional description Set throttle effective starting point Suggestion Set accord...

Page 19: ...ective 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 r...

Page 20: ...al 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...

Page 21: ...tle and turn the throttle again or turn on the brake switch will make the Cruise control quit Suggestion factory default is Disable 27 Anti Slip If enabled the controller will try to prevent the vehic...

Page 22: ...lue 110 C The controller will resume work when the motor temp is at 110 degrees inside Range 60 170 6 Line Hall Zero It is only useful when the speed sensor is at 4 Useless for KLS N or KLS M model 4...

Page 23: ...mit in Torque Mode Range 50 4000 Factory set is 1000 These three parameters are used for PID adjustment If you think the acceleration performance is very very strong please adjust them to a lower valu...

Page 24: ...onitor screen of user program it 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 mu...

Page 25: ...Kelly KLS N Sinusoidal Brushless Permanent Magnet Motor Controller User s Manual V2 9 23 2 Please connect the controller to user program by using an USB to RS232 cable and SM 4A DB9 RS232 Converter...

Page 26: ...B 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 W...

Page 27: ...g 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 fi...

Page 28: ...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 writ...

Page 29: ...e 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...

Page 30: ...n 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 s...

Page 31: ...t 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 res...

Page 32: ...et Motor Controller User s Manual V2 9 30 Contact Us Kelly Controls Home Page http www KellyController com Download user manual instructions and user program www kellycontroller com support php E mail...

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