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Kelly KLS6022H User Manual Download Page 35

Kelly KLS-H Brushless Motor Controller User’s Manual

V 1.10

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:

[email protected]

Phone:

(01) 224 637 5092

Summary of Contents for KLS6022H

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 V 1 10 Rev 1 10 Jun 2017 ...

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 15 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: ...s 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 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 ...

Page 6: ...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 you don t turn throttle at all 14 12V brake swi...

Page 7: ...ery voltage 13 Rugged aluminum 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 wo...

Page 8: ...Operating Temperature Range 40 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 i...

Page 9: ...es voltage is 18V 120V 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 metal surface with four screws Applying silicon grease or ...

Page 10: ...Kelly KLS H Brushless Motor Controller User s Manual V 1 10 7 Figure 1 KLS7215H KLS7218H KLS6022H KLS6030H KLS7230H mounting holes dimensions dimensions in millimeters ...

Page 11: ...Kelly KLS H Brushless Motor Controller User s Manual V 1 10 8 Figure 2 KLS7245H mounting holes dimensions dimensions in millimeters ...

Page 12: ...Kelly KLS H Brushless Motor Controller User s Manual V 1 10 9 Figure 3 KLS7250H mounting holes dimensions dimensions in millimeters ...

Page 13: ...Kelly KLS H Brushless Motor Controller User s Manual V 1 10 10 Figure 4 KLS7275H mounting holes dimensions dimensions in millimeters ...

Page 14: ...Kelly KLS H Brushless Motor Controller User s Manual V 1 10 11 Figure 5 KLS72xxx 8080H KLS96xxx 8080H mounting holes dimensions dimensions in millimeters ...

Page 15: ...e same pin as pin2 When Boost 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 r...

Page 16: ...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 Caution Do not apply power until you are certain the controller wiring is correct and has been double checked Wiring fault...

Page 17: ...Kelly KLS H Brushless Motor Controller User s Manual V 1 10 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: ...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 version Both functions can be used at the same time KLS controller can support KTY84 150 and KTY84 130 thermistor...

Page 19: ...P 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 behind the vehicle during the c...

Page 20: ...ehicle 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 Tablet is prefered First of all people need to do Identification angle function for KLS controller before running the ...

Page 21: ...Identification Angle Please download the instruction to how to use Identification angle function 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 th...

Page 22: ... 5 40 Functional description Set throttle effective starting point Suggestion Set according to the practical situation 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 rege...

Page 23: ...o 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 signal the controller will not operate and report fault code Suggestion Set according to t...

Page 24: ... 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 Disable Disable x OFF x Forward x ON x Reverse Note X means ca...

Page 25: ...eration please just choose Change Direction item Please click Write button to activate Change Direction function The motor direction will be what you expected after the power supply is reset Suggestion factory default is Disable 4 2 Step 2 1 Motor Poles Motor Poles The pair pole number 2 Range 2 128 Suggestion Set according to the real motor poles on the nameplate of the motor factory default is a...

Page 26: ...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 time of Brake Torque from 0 to max accuracy 0 1s Range 1 250 Factory set is 15 6 Brake Rls Time Brake Release Time the time of Brake Torque from max to 0 accuracy 0 1s Range 1 250 Factory set is 1 7 BRK_SW Brk BRK_SW Braking Percent the percent o...

Page 27: ...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 Identification angle operation before running motor for all KLS controllers The Identification angle operation can be done in PC program or Android...

Page 28: ...Kelly KLS H Brushless Motor Controller User s Manual V 1 10 25 2 Please connect the controller to user program by using an USB to RS232 cable and SM 4A DB9 RS232 Converter ...

Page 29: ...S232 converter any more when you 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 c...

Page 30: ... power supply is off for a few seconds The beeper will send a constant beep after the power supply is turned on The motor shaft will try to run on directions randomly It is normal because the controller is doing Identification angle operation 7 Please wait about 2 3 minutes 8 If the identification angle operation is finished the constant beep sound will be disappeared The beeper will beep an error...

Page 31: ...ep 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 time as long as you 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 identi...

Page 32: ...nnect 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 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 b...

Page 33: ...entify 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 will have cut back or stopped regen 4 This only accurate to 2 upon Overvoltage setting 1 3 Low voltage error 1 The controller will clear after 5 seconds if battery volts returns to normal 2 Check battery volts recharge if required 1 4 ...

Page 34: ...rmal 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 instruction from our website 2 Incorrect wiring 3 Speed sensor is damaged or defective Or feedback signal is er...

Page 35: ...oller User s Manual V 1 10 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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