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Kelly KLS-D Brushless Motor Controller User’s Manual

V1.5.02

Kelly KLS-D Brushless Motor

Controller User’s Manual

Devices Supported:

Rev.1.5.02

October.2015

KLS4840D

KLS7240D

KLS4850D

KLS7250D

KLS6040D

KLS7275D

KLS6050D

Содержание KLS4840D

Страница 1: ...S D Brushless Motor Controller User s Manual V1 5 02 Kelly KLS D Brushless Motor Controller User s Manual Devices Supported Rev 1 5 02 October 2015 KLS4840D KLS7240D KLS4850D KLS7250D KLS6040D KLS7275D KLS6050D ...

Страница 2: ...l functions 3 2 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 7 3 3 Installation Check List 11 Chapter 4 Programmable Parameters 12 4 1 Step 1 12 4 2 Step 2 16 4 3 Step 3 17 Chapter 5 Maintenance 18 5 1 Cleaning 18 5 2 Configuration 19 Table 1 ERROR CODES 20 Contact Us 21 ...

Страница 3: ...ased on sinusoidal wave driving technology to reduce the operation noise and 1 3 switching loss which well meets the noise reduction and efficiency requirements 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 allow...

Страница 4: ...sion of a 5 volt and 12 volt output to supply various kinds of 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 2 analog 0 5V inputs that default to throttle input and motor temperature input 12 Copy signal of one of hall sensors 13 Configurable boost switch Enables the maximum outpu...

Страница 5: ...ed aviation connectors for small signal 15 Thermal protection current cut back warning and shutdown on high temperature 16 Configurable 60 degree or 120 degree hall position sensors 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 detected at power on 18 Current multiplication Ta...

Страница 6: ...ge 0 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 50D KLS Kelly BLDC motor controller based on sinusoidal waveform which is supposed to work with BLDC motor with three hall sensors 72 72V batteries 50 The matched motor is 72V 5KW BLDC motor with hall ...

Страница 7: ...o 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 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...

Страница 8: ...er Figure 2 waterproof connector DJ7091Y 2 3 11 Pin Definition 14 REV_SW Reverse switch input Orange 6 RTN Signal return or power supply return Black 12 FWD Forward switch White 11 12V 12V Source Red 25 12V brake switch Yellowish 9 Relay Main contactor driver Blue 33 CAN H Green 7 PWR Controller power supply input Pink ...

Страница 9: ...ase 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 faults will damage the controller Ensure that the B wiring is securely and properly co...

Страница 10: ...Kelly KLS D Brushless Motor Controller User s Manual V 1 5 02 9 3 2 2 Standard Wiring of KLS D Controller Figure 3 KLS D controller standard wiring Battery voltage can be used for controller supply ...

Страница 11: ...igure 4 Wiring of brake switch 12V 12V is provided by external source Figure 5 Wiring of brake switch 12V 12V is provided by KLS D controller on pin11 Figure 6 Wiring diagram for motor temperature sensor NOTE The motor temperature sensor and brake switch used the same I O port on pin1 Both functions can not be used at the same time KLS controller can support KTY84 150 and KTY84 130 thermistors ...

Страница 12: ...3 3 Installation Check List Before operating the vehicle complete the following checkout procedure Use LED 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 ...

Страница 13: ...o do Identification angle function for KLS controller before running the motor The controller needs to be connected to batteries motor and throttle before 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 Identification angle function from our website www kellycon...

Страница 14: ... blink error code This is normal Please reset the power supply 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 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 out...

Страница 15: ... at 100 14 Max Rev Speed The reverse speed of the percentage of maximum speed Range 20 100 By default it is set at 100 15 PWM Frequency Frequency of PWM operation Unit KHz Functional description 20KHz is better for hub motor with strict quiet control Suggestion Set according to the practical situation factory default is 20KHz Please don t set it 20KHz above Value Range 10KHz or 20KHz 16 Start up H...

Страница 16: ...V to 0V is backward 2 4V to 2 6V is the throttle dead zone Customers can adjust the throttle dead zone in user program also Please note the common throttle will spring back to original position if you release the throttle Suggestion factory default is Disable 20 Three Gears switch It is used for function of F N R control Please check the wiring diagram in the manual for F N R control Suggestion Se...

Страница 17: ...fault is Disable 23 Cruise Control Value range Enable and Disable If enable if you hold throttle at certain position about 3 4 seconds the controller will get into Cruise control Release throttle and turn the throttle again or turn on the brake switch will make the Cruise control quit Suggestion factory default is Disable 24 Change Direction If the direction is not what you expected after finish t...

Страница 18: ...gen 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 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 A...

Страница 19: ...le Change Dir brake item in user program It will help the motor change the 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 or 150 Chapter 5 Maintenance There are no user serviceable parts inside the controllers Do not attempt to open the controller as this will void your warran...

Страница 20: ...ided by Kelly to connect to a host computer Provide 18V to PWR for a 24V controller provide 8V Wire power supply return supply negative to any RTN pin KLS controller requires a 4pin connector to Kelly RS232 Converter to support the communication And customers may need a Z TEK USB cable for Tablet with Android OS Customers may download PC software or Android APP to program the controller before run...

Страница 21: ...an 2 1 Motor did not start Motor did not reach 25 electrical RPM within 2 seconds of start up Hall sensor or phase wiring problem 2 2 Internal volts fault 1 Measure that B PWR are correct when measured to B or RTN 2 There may be excessive load on the 5V supply caused by too low a value of Regen or throttle potentiometers or incorrect wiring 3 Controller is damaged Contact Kelly about a warranty re...

Страница 22: ... regen The voltage threshold detection level is set during configuration 4 2 Hall sensor error 1 Incorrect or loose wiring or a damaged hall sensor 2 Also be caused by incorrect hall angle configuration 60 degree or 120 degree 4 3 Motor over temperature Motor temperature has exceeded the configured maximum The controller will shut down until the motor temperature cools down Customers may read erro...

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