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Kelly KLS-S Brushless Motor Controller User’s Manual

V1.5.02

3

Chapter 2 Features and Specifications

2.1 General functions

(1) Extended fault detection and protection. The LED flashing pattern indicates the fault

sources.Customers can read the error code in PC software or Android Tablet also.

(2) Monitoring battery voltage. It will stop driving if the battery voltage is too high and it will

progressively cut back motor drive power as battery voltage drops until it cuts out
altogether at the preset “Low Battery Voltage” setting.

(3) Built-in current loop and over current protection.
(4) Configurable motor temperature protection range.
(5) Current cutback at low temperature and high temperature to protect battery and controller.

The current begins to ramp down at 90

case temperature, shutting down at 100

.

(6) The controller keeps monitoring battery recharging voltage during regen braking.
(7) Maximum reverse speed and forward speed can be configured between 20% and 100%

respectively and separately.

(8) A 4pin connector to RS232 port and a Z-TEK USB to RS232 cable allows for configuration,

programming and software upgrades using the tablet which must be based on Android OS
now.People can do the same things on PC software by using a standard USB to RS232
cable instead.

(9) Provision 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 output power achievable if the switch is

turned on.

(14) 12V brake switch input used different port from motor temperature sensor.You can use

both brake switch and motor temperature sensor functions at the same time on the latest
version.Pin 25 is 12V brake switch input port.Pin1 is motor temperature sensor input port.

(15) Optional joystick throttle. A bi-symmetrical 0-5V signal for both forward and reversing.
(16) Configurable motor over-temperature detection and protection with the recommended

thermistor KTY84-130 or KTY84-150.

(17) 3 hall position sensor inputs. Open collector, pull up provided.
(18) Enhanced regen brake function. A novel ABS technique provides powerful and smooth

regen.The regen can happen at any speeds until zero speed.

Caution! The regen is not a safe function.Usually you may use the mechanical brake.

Содержание KLS6040S

Страница 1: ...Brushless Motor Controller User s Manual V1 5 02 Kelly KLS S Brushless Motor Controller User s Manual Devices Supported Rev1 5 02 Sep 2015 KLS4812S KLS7212S KLS6018S KLS7230S KLS6025S KLS6040S KLS603...

Страница 2: ...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 11 3 3 Installation Check List 15 Chapter 4 Pro...

Страница 3: ...al waveform control technology this technique based on sinusoidal wave driving technology to reduce the operation noise and 1 3 switching loss which well meets the noise reduction and efficiency requi...

Страница 4: ...e based on Android OS now People can do the same things on PC software by using a standard USB to RS232 cable instead 9 Provision of a 5 volt and 12 volt output to supply various kinds of hall sensors...

Страница 5: ...d rugged aviation connectors for small signal 16 Thermal protection current cut back warning and shutdown on high temperature 17 Configurable 60 degree or 120 degree hall position sensors 18 Controlle...

Страница 6: ...ature 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 si...

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 su...

Страница 8: ...Kelly KLS S Brushless Motor Controller User s Manual V1 5 02 7 Figure 2 KLS6018S mounting holes dimensions dimensions in millimeters...

Страница 9: ...Kelly KLS S Brushless Motor Controller User s Manual V1 5 02 8 Figure 3 KLS6025S mounting holes dimensions dimensions in millimeters...

Страница 10: ...Kelly KLS S Brushless Motor Controller User s Manual V1 5 02 9 Figure 4 KLS6030S KLS7230S mounting holes dimensions dimensions in millimeters...

Страница 11: ...Kelly KLS S Brushless Motor Controller User s Manual V1 5 02 10 Figure 5 KLS6040S KLS7240S mounting holes dimensions dimensions in millimeters...

Страница 12: ...ntroller Figure 6 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 Sourc...

Страница 13: ...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 no...

Страница 14: ...hless Motor Controller User s Manual V1 5 02 13 3 2 2 Wiring of KLS S Controller 3 2 2 1 Standard wiring of KLS S controller Figure 7 KLS S controller standard wiring Battery voltage can be used for c...

Страница 15: ...gure 8 Wiring of brake switch 12V 12V is provided by external source Figure 9 Wiring of brake switch 12V 12V is provided by KLS S controller on pin11 Figure 10 Wiring diagram for motor temperature sen...

Страница 16: ...ehicle 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 tes...

Страница 17: ...ed First of all people need to do Identification angle function for KLS controller before running the motor The controller needs to be connected to batteries motor and throttle before Identification o...

Страница 18: ...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 a...

Страница 19: ...it is set 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 descript...

Страница 20: ...5V is forward 2 4V 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 origina...

Страница 21: ...Set according to the practical situation factory default 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...

Страница 22: ...0V for Mars 1114 1115 1302 1304 from Motenergy company Value Range 0 1023 maps 0 5V 6 Line Hall Amplitude The position signal based on Zero crossing point It is only useful when the speed sensor is a...

Страница 23: ...1 250 Factory set is 1 7 BRK_SW Brk BRK_SW Braking Percent the percent of BRK_SW in max braking Range 0 50 The brake switch regen mode You have to turn on the brake switch after the throttle is releas...

Страница 24: ...nnecting 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...

Страница 25: ...or Identification Angle operation Configuration software will be regularly updated and published on the website Please Update your Configuration Software regularly You must uninstall the older version...

Страница 26: ...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 Frequent reset May be caused b...

Страница 27: ...t power on as a confidence check and then normally stays Off 1 2 means the Red flashes once and after a second pause flashes twice The pause time between multiple flash code groups is two seconds Cont...

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