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Kelly KLS-S Brushless Motor Controller User’s Manual

V1.10

14

Figure 9:

Wiring of brake switch(12V): 12V is provided by KLS-S controller on pin11

Figure 10: Wiring diagram for motor temperature sensor

3.2.3 Communication Port

A 4pin connector to RS232 port is provided to communicate with host computer for calibration and

configuration.

Figure 11:

RS232 Interface on 4pin connector to RS232 converter

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Содержание KLS-S

Страница 1: ...y KLS S Brushless Motor Controller User s Manual V1 10 Kelly KLS S Brushless Motor Controller User s Manual Devices Supported Rev1 10 Feb 2019 KLS4812S KLS7212S KLS6018S KLS7230S KLS6030S KLS7218S KLS6035S ...

Страница 2: ... 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 16 4 2 Step 2 20 4 3 Step 3 21 4 4 How to use Identification angle operation function 22 Chapter 5 Maintenance 27 5 1 Cleaning 27 5 2 Configuration 27 Table 1 LED CODES 28 Contact Us 30 ...

Страница 3: ...equirements in the application of DC brushless 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 ...

Страница 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 ...

Страница 5: ...ion and harsh environment 15 Rugged high current terminals and rugged aviation connectors for small signal 16 Thermal protection current cut back warning and shutdown on high temperature 17 Controller can do auto_Identification angle for different degrees of hall sensors 18 Configurable high pedal protection the controller will not work if high throttle is detected at power on 19 Current multiplic...

Страница 6: ...to 70 MOSFET temperature 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 30S KLS Kelly BLDC motor controller based on sinusoidal waveform which is supposed to work with BLDC motor with three hall sensors 72 72V batteries S Mini case for the controller Kelly KLS S Brushless Motor...

Страница 7: ...nants 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 shown in Figu...

Страница 8: ...Kelly KLS S Brushless Motor Controller User s Manual V1 10 7 Figure 2 KLS6018S mounting holes dimensions dimensions in millimeters ...

Страница 9: ...Kelly KLS S Brushless Motor Controller User s Manual V1 10 8 Figure 3 KLS7218S mounting holes dimensions dimensions in millimeters ...

Страница 10: ...Kelly KLS S Brushless Motor Controller User s Manual V1 10 9 Figure 4 KLS6030S KLS6035S KLS7230S mounting holes dimensions dimensions in millimeters ...

Страница 11: ... only can be used for LED or switch signals 3 Boost and Brake analog regeneration mode used the 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 DJ7091Y 2 3 11 Pin Definition 14 REV_SW R...

Страница 12: ... 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 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...

Страница 13: ... Motor Controller User s Manual V1 10 12 3 2 2 Wiring of KLS S Controller 3 2 2 1 Standard wiring of KLS S controller Figure 6 KLS S controller standard wiring F N R control Battery voltage can be used for controller supply ...

Страница 14: ...ndard wiring Three speed function control Battery voltage can be used for controller supply 3 2 2 2 Optional wiring of KLS S controller The 12V input signal of the pin supplies the second braking function of the controller Figure 8 Wiring of brake switch 12V 12V is provided by external source ...

Страница 15: ... 12V is provided by KLS S controller on pin11 Figure 10 Wiring diagram for motor temperature sensor 3 2 3 Communication Port A 4pin connector to RS232 port is provided to communicate with host computer for calibration and configuration Figure 11 RS232 Interface on 4pin connector to RS232 converter ...

Страница 16: ...user program while the motor is still running let alone change the settings in the user program Make sure the wire is connected correctly Turn the PWR switch on The Green LED stay on steadily and Red LED turns off when the controller operates normally If this does not happen check continuity of the PWR and return The fault code will be detected automatically at restart With the brake switch open s...

Страница 17: ...ase 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 18 90 Controller will not operate when battery voltage is near the value so as to protect battery Suggestion Set according to the practical situation By default it is set at 18V 2 Over Volt The max voltage of ...

Страница 18: ...he 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 0 86V to 4 2V Our controller will report 3 3 error code if the output of hall throttle i...

Страница 19: ...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...

Страница 20: ...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 poistion 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...

Страница 21: ... 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...

Страница 22: ...unction 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 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 Other...

Страница 23: ... the percent of Neutral Braking in max braking Range 0 50 Only useful when you enable Three gears switch 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...

Страница 24: ...t is Disable 11 Compensation Per Tried to increase the current usage during Anti Slip operation 12 IVT BRK MAX and IVT BRK MIN These two items are only useful when Joystick function 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 on...

Страница 25: ... three hall sensors By default the speed sensor type is set at 2 from factory setting for KLS S controller 1 Please hook up 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 Conv...

Страница 26: ...hird 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 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 ...

Страница 27: ...our 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 shows the Write operation is successful Please quit from the user program Please turn off the power supply 6 Please turn on the power supply after the power supply is off for a few seconds The Green and ...

Страница 28: ...ser 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 or you don t want to wait the identification angle operation any more Otherwise the controller will try to...

Страница 29: ...a load such as a contactor coil resistor or a horn across the controller s B and B terminals Remove any dirt or corrosion from the bus bar area The controller should be wiped with a moist rag Make sure that the controller is dry before reconnecting 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 ...

Страница 30: ...gularly updated and published on the website Please Update your Configuration Software regularly You must uninstall the older version before updating Please try to use Identify function for motor and hall sensors in the user program Table 1 LED CODES Green LED Codes LED Code Explanation Solution Green Off No power or switched off 1 Check if all wires are correct 2 Check fuse and power supply Green...

Страница 31: ...l restart when temperature falls below 80 2 4 Throttle error at power up Throttle signal is higher than the preset dead zone at Power On Fault clears when throttle is released 3 1 Reserved 3 2 Internal reset May be 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...

Страница 32: ...nly valid for KLS 8080I controller Customers may read error codes in PC software or Android Tablet Contact Us Kelly Controls Inc 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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