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Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User

’s Manual

V2.9

Kelly High-current series KLS-N

Sinusoidal Brushless Permanent Magnet Motor Controllers

User’s Manual

Devices Supported:

KLS4860NG

KLS7260NG

KLS8475N

KLS4860NE

KLS7260NE

KLS84100N

KLS4875N

KLS7275N

KLS84120N

KLS48100N

KLS72100N

KLS48120N

KLS72120N

Rev. 2.9

Содержание KLS8475N

Страница 1: ...er s Manual V2 9 Kelly High current series KLS N Sinusoidal Brushless Permanent Magnet Motor Controllers User s Manual Devices Supported KLS4860NG KLS7260NG KLS8475N KLS4860NE KLS7260NE KLS84100N KLS4875N KLS7275N KLS84120N KLS48100N KLS72100N KLS48120N KLS72120N Rev 2 9 ...

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 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 22 4 4 How to use Identification angle operation function 24 Chapter 5 Maintenance 29 5 1 Cleaning 29 5 2 Configuration 29 Table 1 Error Codes 30 Contact...

Страница 4: ...r 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 custom...

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 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 ...

Страница 6: ...n 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 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 prote...

Страница 7: ...ith 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 Opera...

Страница 8: ...r 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 holes dimensions are ...

Страница 9: ...Kelly KLS N Sinusoidal Brushless Permanent Magnet Motor Controller User s Manual V2 9 7 Figure 8 KLS4860NE KLS7260NE mounting holes dimensions dimensions in millimeters B B U V W M8 ...

Страница 10: ...Brushless Permanent Magnet Motor Controller User s Manual V2 9 8 Figure 9 KLS4875N KLS7275N KLS48100N KLS72100N KLS48120N KLS72120N KLS8475N KLS84100N KLS84120N mounting holes dimensions dimensions in millimeters B B U V W M8 ...

Страница 11: ...Brushless Permanent Magnet Motor Controller User s Manual V2 9 9 Figure 10 With Aluminum Liquid Cooling Heatsink at the bottom Only for KLS4860NE and KLS7260NE mounting holes dimensions dimensions in millimeters B B U V W M8 ...

Страница 12: ...LS N Sinusoidal Brushless Permanent Magnet Motor Controller User s Manual V2 9 10 Figure 11 With Aluminum Liquid Cooling Heatsink at the bottom mounting holes dimensions dimensions in millimeters B B U V W M8 ...

Страница 13: ...2V 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 disabled in user program pin2 is used as brake analog regen mode When boost is enable pin2 is used for boost function You may not use two functions at the same time DJ7091Y 2 3 11 Pin Definition 14 REV_SW Reverse switch ...

Страница 14: ...emp 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 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 4 F N R control and three speed function can not be used at the same time They b...

Страница 15: ...anual V2 9 13 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 input signal of the pin supplies the second braking function of the controller ...

Страница 16: ...ake 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 Communication Port A 4pin connector to RS232 port is provided to communicate with host computer for calibration and configuration Figure 15 RS232 Interface on 4pin connector to RS232 converter ...

Страница 17: ...directly 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 The fault code will be detected automatically at restart With the brake switch open select a direction and operate the throttle The motor should spin in the selected direction Verify wiring or voltage ...

Страница 18: ...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 kellycontroller com support php 4 1 Step 1 1 Low Volt The min voltage of reporting this fault Range 20 86 depending on model Controller will not operate whe...

Страница 19: ...e 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 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 o...

Страница 20: ...K 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 factory default is 20 5V 1 0V 13 Brake sensor Dead High Brake sensor Dead Zone High Range 60 95 Functional description Set throttle effective ending point Suggestion Se...

Страница 21: ...fective 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 range Enable and Disable Functional description If enabled the controller will detect the current pedal status when release the brake If throttle got effective output the controller will report fault ...

Страница 22: ...nal 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 and Disable Functional description If enabled the foot switch will be activated The controller will not accept the throttle signal if the foot switch is turned off Please see figure 4 1 Suggestion Se...

Страница 23: ...ttle 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 vehicle rolling back on downhill faster and faster If the ratio of gearbox is high it can try to help the motor stop on the downhill But usually this function only helps motor stop rolling back too fast S...

Страница 24: ...alue 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 3 Step 3 1 RLS_TPS Brk RLS TPS Braking Percent the percent of Releasing Pedal BRK in max braking Range 0 50 This is used to adjust the regen current of releasing throttle regen mode type The regen wi...

Страница 25: ...imit 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 value respectively 10 Change Dir brake Value range Enable and Disable It is only useful when you Enable the joystick function If you want to get swift direction changing by using joystick function you ma...

Страница 26: ...monitor 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 must do Identification 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 N M controller i...

Страница 27: ...Kelly KLS N Sinusoidal Brushless Permanent Magnet Motor Controller User s Manual V2 9 25 2 Please connect the controller to user program by using an USB to RS232 cable and SM 4A DB9 RS232 Converter ...

Страница 28: ...SB 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 We don t have to use SM 4A to DB9 RS232 converter any more when you use Bluetooth converter for programming the controller ...

Страница 29: ...ng 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 give a pop up window which show the Write operation is successful Please quit from the user program Ple...

Страница 30: ...r 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 Otherwise the controlle...

Страница 31: ...re 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 ple...

Страница 32: ...on 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 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 Controlle...

Страница 33: ...lt 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 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 ins...

Страница 34: ...net Motor Controller User s Manual V2 9 32 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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