Kelly KLS7240ND User Manual Download

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Kelly Jaguar series KLS-N Sinusoidal Brushless PM Motor Controller User

’s Manual

V2.9

Kelly Jaguar series KLS-N

Modest size & all around Sinusoidal Brushless PM Motor Controllers

User’s Manual

Devices Supported:

KLS2412ND

KLS4812ND

KLS7212ND

KLS8430ND

KLS2412N

KLS4812N

KLS7212N

KLS8430N

KLS2418ND

KLS4818ND

KLS7215ND

KLS2418N

KLS4818N

KLS7215N

KLS2430ND

KLS4830ND

KLS7218ND

KLS2430N

KLS4830N

KLS7218N

KLS7230ND

KLS7230N

KLS7240ND

KLS7240N

Rev. 2.9

Feb. 2023

Summary of Contents for KLS7240ND

Page 1: ...around Sinusoidal Brushless PM Motor Controllers User s Manual Devices Supported KLS2412ND KLS4812ND KLS7212ND KLS8430ND KLS2412N KLS4812N KLS7212N KLS8430N KLS2418ND KLS4818ND KLS7215ND KLS2418N KLS...

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 Paramet...

Page 3: ...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 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 t...

Page 5: ...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 6: ...al Full Power Operating Temperature Range 0 to 70 MOSFET temperature Operating Temperature Range 40 to 100 MOSFET temperature Max Battery Current Configurable 2 4 Name Regulation The name regulation o...

Page 7: ...S7218ND 48 72V 36 86V 240A Up to 130A KLS7218N 48 72V 36 86V 240A 80A 120A KLS7230ND 48 72V 36 86V 280A Up to 150A KLS7230N 48 72V 36 86V 280A 90A 135A KLS7240ND 48 72V 36 86V 320A Up to 160A KLS7240N...

Page 8: ...ller 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...

Page 9: ...y Jaguar series KLS N Sinusoidal Brushless PM Motor Controller User s Manual V2 9 8 Figure 3 KLS2418ND KLS2430ND KLS4818ND KLS4830ND KLS7218ND KLS7222ND mounting holes dimensions dimensions in millime...

Page 10: ...elly Jaguar series KLS N Sinusoidal Brushless PM Motor Controller User s Manual V2 9 9 Figure 4 KLS2418N KLS2430N KLS4818N KLS4830N KLS7218N KLS7222N mounting holes dimensions dimensions in millimeter...

Page 11: ...Kelly Jaguar series KLS N Sinusoidal Brushless PM Motor Controller User s Manual V2 9 10 Figure 5 KLS7230ND KLS7240ND KLS8430ND mounting holes dimensions dimensions in millimeters...

Page 12: ...Kelly Jaguar series KLS N Sinusoidal Brushless PM Motor Controller User s Manual V2 9 11 Figure 6 KLS7230N KLS8430N mounting holes dimensions dimensions in millimeters...

Page 13: ...Kelly Jaguar series KLS N Sinusoidal Brushless PM Motor Controller User s Manual V2 9 12 Figure 7 KLS7240N mounting holes dimensions dimensions in millimeters...

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...

Page 15: ...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...

Page 16: ...f 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 input signal of the pin supplies the s...

Page 17: ...ng 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...

Page 18: ...e 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 rest...

Page 19: ...n7 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 T...

Page 20: ...ly 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...

Page 21: ...gh 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...

Page 22: ...ctive 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 use...

Page 23: ...oot 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...

Page 24: ...elp 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 expe...

Page 25: ...less 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 thrott...

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 w...

Page 27: ...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 opera...

Page 28: ...Kelly Jaguar series KLS N Sinusoidal Brushless PM 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: ...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 30: ...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 31: ...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 32: ...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 33: ...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 34: ...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 35: ...PM 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...

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