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Kelly KLS-H Sinusoidal Brushless Permanent Magnet Motor Controller User

’s Manual

V1.2

Kelly KLS-H

Sinusoidal Brushless Permanent Magnet Motor Controllers

User’s Manual

Devices Supported

KLS6045H

KLS7222H

KLS8422H

KLS96401-8080H

KLS6045HC

KLS7222HC

KLS8422HC

KLS96501-8080H

KLS7230H

KLS8430H

KLS7230HC

KLS8430HC

KLS7275H

KLS84501-8080H

KLS7275HC

KLS84601-8080H

Rev.1.2

Apr. 2023

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Содержание KLS6045H

Страница 1: ...elly KLS H Sinusoidal Brushless Permanent Magnet Motor Controllers User s Manual Devices Supported KLS6045H KLS7222H KLS8422H KLS96401 8080H KLS6045HC KLS7222HC KLS8422HC KLS96501 8080H KLS7230H KLS8430H KLS7230HC KLS8430HC KLS7275H KLS84501 8080H KLS7275HC KLS84601 8080H Rev 1 2 Apr 2023 ...

Страница 2: ... Features 4 2 3 Specifications 5 2 4 Name Regulation 6 Chapter 3 Wiring and Installation 6 3 1 Mounting the Controller 6 3 2 Connections 11 3 3 Installation Check List 15 Chapter 4 Programmable Parameters 16 4 1 Step 1 16 4 2 Step 2 21 4 3 Step 3 21 4 4 How to use Identification angle operation function 23 Chapter 5 Maintenance 27 5 1 Cleaning 27 5 2 Configuration 27 Table 1 Error Codes 28 Contact...

Страница 3: ...s 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 and Android App There is one more choice for ...

Страница 4: ... 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 if you don t turn throttle at all 14...

Страница 5: ...ery voltage 13 Rugged aluminum housing for maximum heat dissipation and harsh environment 14 Rugged high current terminals and rugged aviation connectors for small signal 15 Thermal protection current cut back warning and shutdown on high temperature 16 Controller can do auto_Identification angle for different degrees of hall sensors 17 Configurable high pedal protection the controller will not wo...

Страница 6: ...H and KLS 8080H model are non isolated type controllers Supply Current PWR 30mA Typical Configurable battery voltage range B KLS24V model B Max operating range 20V to 30V 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 ...

Страница 7: ...1 Minute Peak Current Amp Continuous Current Amp Nominal Voltage Volt Max Operating Voltage Volt KLS6045H 380 130 48 60 80 KLS6045HC 380 130 48 60 80 KLS7222H 220 80 48 72 86 KLS7222HC 220 80 48 72 86 KLS7230H 300 100 48 72 86 KLS7230HC 300 100 48 72 86 KLS7275H 450 160 48 72 86 KLS7275HC 450 160 48 72 86 KLS8422H 220 80 48 84 100 KLS8422HC 220 80 48 84 100 KLS8430H 300 100 48 84 100 KLS8430HC 300...

Страница 8: ...ilicon 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 Figure 1 2 3 4 Figure 1 KLS7222H KLS7222HC KLS7230H KLS7230HC KLS8422H KLS8422HC KLS8430H KLS8430HC mounting holes dimensions dimension...

Страница 9: ...Kelly KLS H Brushless Motor Controller User s Manual V 1 2 8 Figure 2 KLS7245H KLS7245HC mounting holes dimensions dimensions in millimeters ...

Страница 10: ...Kelly KLS H Sinusoidal Brushless Permanent Magnet Motor Controller User s Manual V 1 2 9 Figure 3 KLS7275H KLS7275HC mounting holes dimensions dimensions in millimeters ...

Страница 11: ...Kelly KLS H Brushless Motor Controller User s Manual V 1 2 10 Figure 4 KLS84501 8080H KLS84601 8080H KLS96401 8080H KLS96501 8080H mounting holes dimensions dimensions in millimeters ...

Страница 12: ... 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 Figure 5 waterproof connector DJ7091Y 2 3 11 Pin Definition 14 REV_SW Reverse switch input Orange 6 RTN Signal return or p...

Страница 13: ...put 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 been double checked W...

Страница 14: ... Sinusoidal Brushless Permanent Magnet Motor Controller User s Manual V 1 2 13 3 2 2 Standard Wiring of KLS H Controller Figure 6 KLS H controller standard wiring Battery voltage can be used for controller supply ...

Страница 15: ...7 Wiring of brake switch 12V 12V is provided by external source Figure 8 Wiring of brake switch 12V 12V is provided by KLS D controller on pin11 Figure 9 Wiring diagram for motor temperature sensor NOTE The motor temperature sensor and brake switch used the different I O port on latest version Both functions can be used at the same time KLS controller can support KTY84 150 and KTY84 130 thermistor...

Страница 16: ...igure 11 SM 4P connector for communication interface on KLS H controller 3 3 Installation Check List Before operating the vehicle complete the following checkout procedure Use buzzer 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...

Страница 17: ...working environment so as to be at its best The default parameters of the controller are not recommended for all applications Make sure set the proper parameters before making any test to avoid danger Customers can do program on PC software or Android App The Android Tablet is prefered First of all people need to do Identification angle function for KLS controller before running the motor The cont...

Страница 18: ...is stable and normal Please fill in 170 for Identification Angle item in user program Then please click Write button in user program Please wait a few seconds before restart the power supply You will see some info on Monitor screen after power supply is reset If you see Reset error on the Monitor screen that is to say the auto_Identification is finished You can see 85 in the Identification Angle i...

Страница 19: ...he practical situation factory default is 80 5V 4 0V 11 Brake sensor type Brake sensor type for brake variable regen mode 1 0 5V 3 wire 0 5K pot 5K is normal 2K 20K 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 according to the practical situation facto...

Страница 20: ...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 drive the motor on two directions without using any reversing s...

Страница 21: ... OFF OFF x Neutral OFF ON x Reverse ON OFF x Forward ON ON x Neutral Disable Enable 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 1 25 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 t...

Страница 22: ...is Disable 4 2 Step 2 1 Motor Poles Motor Poles The pair pole number 2 Range 2 128 Suggestion Set according to the real motor poles on the nameplate of the motor factory default is at 8 2 Speed Sensor Type Speed Sensor Type 2 Hal 3 Resolver 4 Line Hall Range 2 4 Different sensors type By default it is set at 2 If you have a motor with 5V Sin Cosin GND speed sensors please choose it at 4 And please...

Страница 23: ...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 released for the regen to occur Factory set is 10 8 Brake Analog regen Brk It is used to adjust the max regen percentage of brake variable regen mode This regen mode doesn t need brake switch to support any more for KLS controller 8 Torqu...

Страница 24: ...tion angle operation before running motor for all KLS controllers The Identification angle operation can be done in PC program or Android App Tablet or Cell Phone KLS D H controller is designed for BLDC motor with three hall sensors By default the speed sensor type is set at 2 from factory setting for KLS D H controller 1 Please hook up the controller for identification angle operation according t...

Страница 25: ...User s Manual V 1 2 24 Customers also can use a Z TEK USB 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 ...

Страница 26: ...ication angle item is at 85 But customers still need to run identification angle operation before driving 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 fill 170 in the identification angle item And please click the write button The user program will ...

Страница 27: ...d there are other error 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 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 O...

Страница 28: ...ure 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 through either an RS232 or USB port Disconnect motor wiring from controller for configuring existing parameters in the user program or Android APP If this operation is too much extra job for you pl...

Страница 29: ...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 suspend the motor when enable Auto Identify function 1 2 Over voltage error 2 Battery voltage is too high for the controller Check battery volts and configuration 3 Regeneration over voltage Controller will have cut back or stopped regen...

Страница 30: ...porary 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 restart will clear the fault 3 4 Angle sensor error 1 Speed sensor type error customers may set the correct sensor type through user program or App Please download how to use Identification function instruction from our websi...

Страница 31: ...oller User s Manual V 1 2 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 Sales Kelly Controls com Phone 01 224 637 5092 ...

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