Kelly KLS-S User Manual V1.5.02
Contents
1. sv Battery pack LVIOW Precharge resistor C Yellow BLDC motor with hall sensors Purple Hal LA Yellow Hal LE Green Hall Sensors Hal 10 Blue GND Black po GND Black Motor_Temp Raddle PWR Pink Key switch 2A Fuse Reverse Orange Forward White 12V Red Boost Brown Boost Switch Raddle Kiji Micro SW Gar 5V Purple Throttle NavyGreen Sona GND Black DJ7061Y 2 3 21 12V Brake Yellowish aN pile o 21 3 h ae Yellow D Green D Bine Brake Switch aa aie rane as an Gs 1 The switch signal is valid to 12V 2 12V only can be used for LED or Switch signals Figure 7 KLS S controller standard wiring Battery voltage can be used for controller supply 13 Kelly KLS S Brushless Motor Controller User s Manual V1 5 02 3 2 2 2 Optional wiring of KLS S controller The 12V input signal of the pin supplies the second braking function of the controller Brake Switch 12V pin25 Brk sy 12V supply From Controller RTN 12V supply Figure 8 Wiring of brake switch 12V 12V is provided by external source Brake Switch 12V pin25 Brk From Controller inl1l 12V Figure 9 Wiring of brake switch 12V 12V is provided by KLS S controller on pin11 KTY84 130 pinl Motor_ Temp From Controller pin6 RTN Figure 10 Wiring diagram for motor temperature sensor2. 19 Joystick function If enable the controller can drive the motor on two directions without using any reversing switch Just one single throttle can drive the motor on forward and reversing direction The stick shift throttle firmware can be called wig wag or joystick operation It is only a software function Usually It is useful for electric boat project You still can use the common 0 5K pot or 0 5V throttle for the controller lf you don t choose the joystick you operated the throttle in this way The motor speed will increase when the throttle is from OV to 5V If you enable joystick for this controller in user program you will start the motor from 2 5V position 2 6V to 5V is forward 2 4V to OV 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 Set according to the practical situation factory default is Disable 20 A Three Gears Switch Value range Enable and Disable Functional 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
3. 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 Set according to the practical situation factory default is Disable Configuration Pin Status Runnin Forward Foot Switch PID REN SW root oe Switch 12 14 15 OFF OFF x Neutral OFF ON X Reverse Enable Disable ON OFF X Forward ON ON x Neutral l X OFF OFF Can t operate Disable Enable x ON OFF Can t operate 19 Kelly KLS S Brushless Motor Controller User s Manual V1 5 02 x ON ON Reverse x OFF ON Forward xX OFF xX Forward Disable Disable ON e Reverse Note X means can be on or off Figure 4 2 21 Boost 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 the throttle is not operated at all The boost function is still based on limiting of the motor current and battery current settings in user program Suggestion Set according to the practical situation factory default is Disable 22 Foot switch lt is used for microswitch If enabled the controller will only accept the throttle signal after received the valid foot switch signal If there is no foot switch signal the controller will ignore the throttle signal Suggestion Set according to the practical situation facto
4. 000 electric RPM standard Electric RPM mechanical RPM motor pole pairs Motor pole pairs Motor poles 2 daa Q Kelly KLS S Brushless Motor Controller User s Manual V1 5 02 2 3 Specifications Frequency of Operation 20KHz e Standby Battery Current lt 0 5mA 5V or 12V Sensor Supply Current 40mA Controller supply voltage range PWR 18V to 90V for controllers rated equal or lower than 72V e Supply Current PWR 30mA Typical Configurable battery voltage range B Max operating range 18V to 1 25 Nominal Voltage Standard Throttle Input 0 5 Volts 3 wire resistive pot 1 4 Volts hall active throttle e Throttle Input 0 5 Volts Can use 3 wire pot to produce 0 5V signal Main Contactor Coil Driver lt 2A Full Power Operating Temperature Range 0 C to 70 C MOSFET temperature Operating Temperature Range 40 Cto 100 C 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 sinusoidal waveform which is supposed to work with BLDC motor with three hall sensors 72 72V batteries 30 The matched motor is 72V 3KW BLDC motor with hall sensors S Mini case for the controller and motor power lt 4KW Kelly KLSS Brushless Motor Controller Model 10 seconds Continuous Voltage Volt Current Amp Current Amp KLS4812S 120 50 24 48
5. KLS7212S 120 50 24 72 KLS6018S 240 100 24 60 KLS6025S 300 120 24 60 KLS6030S 350 150 24 60 KLS6040S 400 175 24 60 KLS7230S 300 120 24 72 KLS7240S 350 150 24 72 1 48V model range of the battery voltage is 24V 48V 1 60V model range of the battery voltage is 24V 60V 3 72V model range of the battery voltage is 24V 72V Kelly KLS S Brushless Motor Controller User s Manual V1 5 02 Chapter 3 Wiring and Installation 3 1 Mounting the Controller The controller can be oriented in any position which should be as clean and dry as possible and if necessary shielded with a cover to 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 holes dimensions are shown in Figure 1 2 3 4 5 Figure 1 KLS4812S KLS7212S mounting holes dimensions dimensions in millimeters Kelly KLS S Brushless Motor Controller User s Manual V1 5 02 148 716 0 0 E O 76 5 l jas Figure 2 KLS6018S
6. Kelly KLS S Brushless Motor Controller User s Manual V1 5 02 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 running the motor You may do Identification angle operation for brushless motor after running the software or Android APP Every item in the configuration program can show the explanation automatically when you click it Caution Make certain that the motor is connected before trying to run Identification angle function in the configuration software 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 Configuration software will be regularly updated and published on the website Please Update your Configuration Software regularly You must uninstall the older version before updating Please try to use Identify function for motor and hall sensors in the user program Table 1 LED CODES Green LED Codes LED Code Explanation Solution Green Off No power or 1 Check if all wires are correct switched off 2 Check fuse and power supply Green On Normal operation That s great You got solution Green 8 Red are both 1 Software needs upgrad
7. select a direction and operate the throttle The motor should spin in the selected direction Verify wiring or voltage and the fuse if it does not The motor should run faster with increasing throttle If not refer to the Table 1 LED code and correct the fault as determined by the fault code Take the vehicle off the blocks and drive it in a clear area It should have smooth acceleration and good power Chapter 4 Programmable Parameters KLS Configuration program allow users to set parameters according to the vehicle actual 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 oeople 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 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 18 90 Controller will not operate when battery voltage is near the value so as to protect battery Suggestion
8. 0 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 Pedal Value range Enable and Disable Functional description If enabled the controller will detect the current pedal status at power up If throttle got effective output the controller will report fault and not operate Suggestion Set according to the practical situation factory default is Enable 17 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 and not operate Suggestion Set according to the practical situation factory default is Disable 18 NTL H Pedal Neutral position High Pedal Disable Only useful when Three gears switch 18 Kelly KLS S Brushless Motor Controller User s Manual V1 5 02 function is enabled If 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
9. 130 C Range 60 170 Resume C Motor High Temp Resume Temp nominal value 110 C The controller will resume work when the motor temp is at 110 degrees inside Range 60 170 5 Line Hall Zero It is only useful when the speed sensor is at 4 Zero Crossing point of Sine Cosine linear hall sensors output signal Usually the Sine Cosine speed sensor supplier provided sensors with 2 5V or 3 0V zero crossing point You can change it back between 2 5V and 3 0V if the motor can not run Suggestion Set according to the practical situation factory default is 613 3 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 at 4 For example if the Line hall Amplitude is 1 1V the signal output of Sine Cosine sensors is from 1 9V to 4 1V 3 1 1 1 9V 3 1 1V 4 1V Value Range 0 1023 maps 0 5V 7 Line Hall High Err It is only useful when the speed sensor is at 4 If the signal output of Sine Cosine speed sensor is above this setting the controller will report hall error Please adjust Line Hall High Err to a higher value to eliminate this error Value Range 0 1023 maps 0 5V 8 Line Hall Low Err It is only useful when the speed sensor is at 4 If the signal output of Sine Cosine speed sensor is below this setting the controller will report hall error also Please adjust Line Hall Low Err to a lower value to elim
10. Kelly KLS S Brushless Motor Controller User s Manual V1 5 02 Kelly KLS S Brushless Motor Controller User s Manual Devices Supported KLS4812S KLS7212S KLS6018S KLS7230S KLS6025S KLS6040S KLS6030S KLS7240S Rev1 5 02 Sep 2015 Kelly KLS S Brushless Motor Controller User s Manual V1 5 02 Contents Chapter 1 Introduction scsisasin dis did dt 2 IO Ia AO A nn O NE 2 Chapter 2 Features and SpecificatiOnsS occoooooononononoonooroaroronarrnos 3 Za General TUNISIA a ace 3 22 FAO A di 4 pS o A ROE 5 24 Name Regala i A EAN A NE ii 5 Chapter 3 Wiring and Installation 6 3 1 Mounting O A ide sdsere at eadeed cadacanvescececstountetraderde saci tdedd ore 6 E A A a aaa eRT 11 3 2 Installation Check ISE ii A AA A ARE 15 Chapter 4 Programmable Parameters ocococcocnoncnoccninoniconanonaconnonanonanonnoranaranonos 16 AMES AA AA IN ANA 16 4 2 Step 2 se ected aed ade clan aheseciates E E aul alas rata dase Sa tanec aT 20 A DSU PDs es ha Secs he lei es Naa hi ER a eek ache hee Se 21 Chapter 5 Maintenant esseeri dail eta nee earn etre nese 23 SA A OA 23 de CONMIGO einen a E a a E Seeedacteasduts 23 Table 1 gt LED CODES rias 24 ContactUs naaa e A A E E EON 26 Kelly KLS S Brushless Motor Controller User s Manual V1 5 02 Chapter 1 Introduction 1 1 Overview This manual introduces the Kelly Small sinusoidal wave brushless BLDC motor controllers features their installation and their maintenance Read the manual ca
11. 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 14 Kelly KLS S Brushless Motor Controller User s Manual V1 5 02 3 2 3 Communication Port A 4pin connector to RS232 port is provided to communicate with host computer for calibration and configuration O O GO O O 6 O Oo 0 O Figure 8 RS232 Interface on 4pin connector to RS232 converter SM 4P Female Figure 9 SM 4P connector for communication interface on KLS S controller 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 e 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 insulated tools e Make sure the wire is connected correctly e Turn the PWR switch on The Green LED stay on steadily and Red LED turns off when the controller operates normally If this does not happen check continuity of the PWR and return 15 Kelly KLS S Brushless Motor Controller User s Manual V1 5 02 e The fault code will be detected automatically at restart e With the brake switch open
12. Set according to the practical situation By default it is set at 18V 2 Over Volt The max voltage of reporting this fault Range 18 90 Controller will not operate when battery voltage is higher than the value so as to protect battery and controller Suggestion Set according to the practical situation By default It is 60V for 48V controller It is 80V for 60V controller It is 90V for 72V controller Controller Rated voltage Under Voltage Range V Over Voltage Range V 48V 18 60 18 60 60V 18 80 18 80 72V 18 90 18 90 Figure 4 1 Kelly KLS S Brushless Motor Controller User s Manual V1 5 02 3 Current Percent Phase Current Percent Range 20 100 Functional description The max motor current is The Value Peak Current of the Controller Suggestion Factory default is 100 4 Battery Limit Battery Limit Current Limit the max value of Battery Current Range 20 100 Functional description Set max battery current so as to protect battery A lower value means a lower battery output current and better protective effect But excessively low value will affect acceleration Suggestion Factory default is 100 5 Identification Angle Please download the instruction to how to use Identification angle function from the website www kellycontroller com support php If you can read 85 in Identification Angle item that is to say the system is stable and normal Please fill in 170 for Identification Angle it
13. ange 0 10000 Factory set is 3000 Torque Speed KI Speed Integral Ki in Torque Mode Range 0 500 Factory set is 80 Speed Err Limit Speed Error Limit 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 9 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 may enable Change Dir brake item in user program It will help the motor change the direction of motor quickly after you shift throttle from OV to 5V or 22 Kelly KLS S Brushless Motor Controller User s Manual V1 5 02 from 5V to OV 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 warranty However periodic exterior cleaning of the controller should be carried out The controller is a high powered device When working with any battery powered vehicle proper safety precautions should be taken that include but are not limited to proper training wearing eye protection avoidance of loose clothing hair and jewelry Always use insulated tools 5 1 Cleaning Although the controller requires virtually n
14. correct wiring 3 Controller is damaged Contact Kelly about a warranty repair 2 3 ao ama Over temperature The controller temperature has exceeded 100 C The controller will be stopped but will restart when temperature falls below 80 C 2 4 xa aaan Throttle error at Throttle signal is higher than the preset dead zone at power up Power On Fault clears when throttle is released 3 1 noo a Frequent reset May be caused by over voltage bad motor intermittent earthing problem bad wiring etc 3 2 aga aa Internal reset May be caused by some transient fault condition like a temporary over current momentarily high or low battery voltage This can happen during normal operation 3 3 poaa ana Hall throttle is open When the throttle is repaired a restart will clear the or short circuit fault 3 4 xaa paan Non zero throttle on Controller won t allow a direction change unless the direction change throttle or speed is at zero Fault clears when throttle is released 4 1 ooon a Regen or Start up Motor drive is disabled if an over voltage is detected over voltage at start up or during regen The voltage threshold detection level is set during configuration 4 2 oo na 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 nooo ooo Motor Motor temperature has exceeded the configured maximum The controller will shut down until
15. e type That is to say these two settings are only useful for hall active throttle or pedal when you chose throtle type at 2 As the same goes it is valid to adjust the high threshold voltage above 4 5V or below 4 5V Usually the hall output voltage is 4 2V Max If you adjust it to lower value which is near 4 2V it may trigger the error code in normal way 17 Kelly KLS S Brushless Motor Controller User s Manual V1 5 02 8 TPS Type TPS Type 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 9 TPS Dead Low TPS 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 10 TPS Dead High TPS Dead Zone High Range 60 95 Functional description Set throttle effective ending point Suggestion Set according to the practical situation factory default is 80 5V 4 0V 11 Max output Fre Max output frequency Unit Hz Functional description It will affect the top speed of the motor Suggestion Set according to the practical situation factory default is 1000Hz Please don t set it 1000HZz above 12 Max Speed Max Speed rpm Range 0 10000 By default it is set at 4000 13 Max Fwd Speed The forward speed of the percentage of maximum speed Range 20 100 By default it is set at 100 14 Max Rev Speed The reverse speed of the percentage of maximum speed Range 20 10
16. em 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 lf 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 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 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 output of hall throttle from Kelly is about from 0 86V to 4 2V Our controller will report 3 3 error code if the output of hall throttle is below 0 5V or above 4 5V by default The controller will think the hall throttle is shorted or damaged if the output is beyond the range from 0 5V to 4 5V You can adjust the threshold voltage below or above 0 5V The controller will report the 3 3 code to protect the system according to different types of hall throttle Because there are many different hall throttle suppliers in the world The initial output can not be always in the range of 0 5V to 4 5V But it doesn t make any differences if you choose 0 5V or 3 wire pot for the throttl
17. inate this error Value Range 0 1023 maps 0 5V 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 will happen as long as the throttle is released completely 21 Kelly KLS S Brushless Motor Controller User s Manual V1 5 02 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 Accel Time Accel Time the time of TPS Torque from 0 to max accuracy 0 1s 5 is equal to 0 5s Range 1 250 Factory set is 10 4 Accel RIs Time Accel Release Time the time of TPS Torque from max to 0 accuracy 0 1s Range 1 250 Factory set is 1 5 Brake Time Brake Time the time of Brake Torque from O to max accuracy 0 1s Range 1 250 Factory set is 15 6 Brake Rls Time Brake Release Time the time of Brake Torque from max to 0 accuracy 0 1s Range 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 released for the regen to occur Factory set is 10 8 Torque Speed KP Speed Percent Kp in Torque Mode R
18. ing On 2 Supply voltage too low or battery too high 3 The controller is damaged Contact Kelly about a warranty repair Red LED Codes LED Code Explanation Solution 1 1 lej a Automatic error 1 Wrong wiring of motor phase line or hall identification Please suspend the motor when enable Auto Identify function 12 le on 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 24 Kelly KLS S Brushless Motor Controller User s Manual 4 This only accurate to 2 upon Overvoltage setting over temperature 1 3 a ana Low voltage error 1 The controller will clear after 5 seconds if battery volts returns to normal 2 Check battery volts 8 recharge if required 1 4 al auna Over temperature 1 Controller case temperature is above 90 C warning Current will be limited Reduce controller loading or switch Off until controller cools down 2 Clean or improve heatsink or fan 2 1 an a 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 pa an Internal volts fault 1 Measure that B amp 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 in
19. ll 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 Kelly KLS S Brushless Motor Controller User s Manual V1 5 02 2 2 Features 1 Intelligence with powerful microprocessor 2 Synchronous rectification ultra low drop fast SVPWM and FOC to achieve very high efficiency Electronic reversing Voltage monitoring on 3 moto
20. ller User s Manual V1 5 02 DJ7091Y 2 3 21 Pin Definition 15 Micro_SW Throttle switch input Gray 3 Throttle Throttle analog input 0 5V Dark Green 1 Temp Motor temperature sensor input Raddle 20 RTN Signal return Black 8 Meter Copy signal of hall sensors Dark Blue 4 5V 5V supply output lt 40mA Purple 2 BOOST Boost function Brown DJ7061Y 2 3 21 Pin Definition 21 RTN Signal return Black 5 5V 5V supply output lt 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 Wiring faults will damage the controller Ensure that the B wiring is securely and properly connected before applying power The preferred connection of the system contactor or circuit breaker is in series with the B line All contactors or circuit breakers in the B line must have precharge resistors across their contacts Lack of even one of these precharge resistors may severely damage the controller at switch on 12 Kelly KLS S Brushless Motor Controller User s Manual V1 5 02 3 2 2 Wiring of KLS S Controller 3 2 2 1 Standard wiring of KLS S controller KLS S Controller
21. mounting holes dimensions dimensions in millimeters Kelly KLS S Brushless Motor Controller User s Manual 58 5 5 V1 5 02 im EE j Lins 90 ep 123 Figure 3 KLS6025S mounting holes dimensions dimensions in millimeters Kelly KLS S Brushless Motor Controller User s Manual V1 5 02 L 111 123 90 140 Figure 4 KLS6030S KLS7230S mounting holes dimensions dimensions in millimeters Kelly KLS S Brushless Motor Controller User s Manual V1 5 02 Figure 5 KLS6040S KLS7240S mounting holes dimensions dimensions in millimeters 10 Kelly KLS S Brushless Motor Controller User s Manual V1 5 02 3 2 Connections 3 2 1 Pin definition of KLS S Controller Orange DJ7091Y 2 3 21 DJ7061Y 2 3 21 1 The switch signal is valid to 12V 2 12V only can be used for LED or Switch signals 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 Source Red 9 Relay Main contactor driver Blue 7 PWR Controller power supply input Pink 25 12V brake switch Yellowish 11 Kelly KLS S Brushless Motor Contro
22. o maintenance after properly installation the following minor maintenance is recommended in certain applications e Remove power by disconnecting the battery starting with battery positive e Discharge the capacitors in the controller by connecting a load such as a contactor coil resistor or a horn across the controller s B and B terminals e Remove any dirt or corrosion from the bus bar area The controller should be wiped with a moist rag Make sure that the controller is dry before reconnecting the battery Make sure 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 e 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 please make sure the motor must be stopped before programming e The controller may display fault code but it doesn t affect programming or configuration But it will affect the Identification angle operation Please try to eliminate the error codes before Identification angle operation Use a straight through RS232 cable or USB converter provided by Kelly to connect to a host computer Provide gt 18V to PWR for a 24V controller provide gt 8V Wire power supply return supply negative to any RTN pin 23
23. r phases bus and power supply Voltage monitoring on voltage source 12V and 5V 6 Current sense on all 3 motor phases 7 Current control loop 8 Hardware over current protection 9 Hardware over voltage protection 10 Configurable limit for motor current and battery current 11 Low EMC 12 LED fault code 13 Battery protection current cutback warning and shutdown at configurable high and low battery voltage 14 Rugged aluminum housing for maximum heat dissipation and harsh environment 15 Rugged high current terminals and 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 Controller can do auto_Identification angle for different degrees of hall sensors 19 Configurable high pedal protection the controller will not work if high throttle is detected at power on 20 Current multiplication Take less current from battery output more current to motor 21 Easy installation 3 wire potentiometer will work 22 Standard PC Laptop computer to do programming There is one more choice for customers to program KLS controller Standard Tablet with Android OS to do programming Need a Z TEK USB TO RS232 cable for connecting the controller to App program in Tablet 23 User program provided Easy to use No cost to customers 24 Support motors with any number of poles 25 Up to 70
24. refully and thoroughly before using the controller If you have any questions please contact the support center of Kelly Controls LLC Kelly s programmable motor controllers provide efficient smooth and quiet controls for electric motorcycles golf carts and go carts as well as industrial motor control It is mainly supposed to solve noise problems of BLDC motor driving application The KLS S motor controller must be based on hall sensors type KLS S controller can not support sensorless brushess motor for now Compared to the traditional trapezoidal 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 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 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 customers to program KLS controller now The APP software is based on Tablet with Android OS Customers may add a Z TEK USB to RS232 cable for programming KLS controller if they want to use Android Tablet Both PC software and Android APP can provide one screen to monitor
25. ry 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 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 the Identification angle operation please just choose Change Direction item Please click Write button to activate Change Direction function The motor direction will be what you expected after the power supply is reset Suggestion factory default 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 defualt it is set at 2 20 Kelly KLS S Brushless Motor Controller User s Manual V1 5 02 If you have a motor with 5V Sin Cosin GND speed sensors please choose it at 4 And please inquire the KLS 8080IPS model before ordering 3 Resolver Poles Resolver Poles The pair pole number 2 Range 2 32 It is only used for the Resolver sensor type 4 Motor Temp Sensor Motor Temp Sensor 0 None 1 KTY84 130 or 150 Range 0 1 High Temp Cut Out C Motor High Temp Cut Out nominal value
26. the V1 5 02 25 Kelly KLS S Brushless Motor Controller User s Manual V1 5 02 motor temperature cools down The Red LED flashes once at 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 Contact Us Kelly Controls LLC Home Page http Awww KellyController com E mail Sales Kelly Controls com Phone 01 224 637 5092 26
27. the controller parameters Sometimes people can use a small Android Tablet as display device Kelly KLS S Brushless Motor Controller User s Manual V1 5 02 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 C case temperature shutting down at 100 C 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 ha
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