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Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User

’s Manual     

 

  V2.9

 

                                                                                                                                         

 

5

 

2.3 Specifications 

Frequency of Operation: 10KHz or 20KHz. 

Standby Battery Current: < 0.5mA. 

5V or 12V Sensor Supply Current: 40mA. 

Supply Current, PWR, 30mA Typical. 

Configurable battery voltage range, B+.   

Standard Throttle Input: 0-5 Volts(3-wire resistive pot), 1-4 Volts(hall active throttle). 

Throttle Input: 0-5 Volts. Can use 3-wire pot to produce 0-5V signal. 

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 of Kelly BLDC motor controllers

 

KLS2412ND 
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 batteries 
N: The motor controller included a plastic cover. And KLS-N is IP66 rating without filling 
the silica gel by default. KLS-N used cast aluminum box as body protection.   
D: stands for conductive 

Kelly KLS-N - Sinusoidal Brushless Permanent Magnet Motor Controller 

Model 

Nominal 

Voltage 

Max Operating 

Voltage 

  Peak Current 

2 Minutes 

Continuous 

Current 

KLS4860NG 

36-48V 

27-60V 

400A 

160A-240A 

KLS4875NC 

36-48V 

27-60V 

500A 

200A-300A 

KLS48100NC 

36-48V 

27-60V 

600A 

240A-360A 

KLS48120NC 

36-48V 

27-60V 

700A 

280A-420A 

KLS7260NG 

48-72V 

36-86V 

400A 

160A-240A 

KLS7275NC 

48-72V 

36-86V 

500A 

200A-300A 

KLS72100NC 

48-72V 

36-86V 

600A 

240A-360A 

KLS72120NC 

48-72V 

36-86V 

700A 

280A-420A 

 
 
 

Содержание KLS4860NE

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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