Related Manuals for Kelly KLS4840D
Summary of Contents for Kelly KLS4840D
- Page 1 Kelly KLS-D Brushless Motor Controller User’s Manual V1.5.02 Kelly KLS-D Brushless Motor Controller User’s Manual Devices Supported: KLS4840D KLS7240D KLS4850D KLS7250D KLS6040D KLS7275D KLS6050D Rev.1.5.02 October.2015...
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Page 2: Table Of Contents
Kelly KLS-D Brushless Motor Controller User’s Manual V1.5.02 Contents Chapter 1 Introduction ....................1.1 Overview..........................2 Chapter 2 Features and Specifications ..............2.1 General functions....................... 3 2.2 Features..........................4 2.3 Specifications........................5 2.4 Name Regulation........................5 Chapter 3 Wiring and Installation ................ -
Page 3: Chapter 1 Introduction
This manual introduces the Kelly sinusoidal wave brushless BLDC motor controllers’ features, their installation and their maintenance. Read the manual carefully and thoroughly before using the controller. If you have any questions, please contact the support center of Kelly Controls, LLC. -
Page 4: Chapter 2 Features And Specifications
Kelly KLS-D Brushless Motor Controller User’s Manual V 1.5.02 Chapter 2 Features and Specifications 2.1 General functions (1) Extended fault detection and protection. 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”... -
Page 5: Features
Kelly KLS-D Brushless Motor Controller User’s Manual V 1.5.02 2.2 Features 1) Intelligence with powerful microprocessor. 2) Synchronous rectification, ultra low drop, fast SVPWM and FOC to achieve very high efficiency. 3) Electronic reversing. 4) Voltage monitoring on 3 motor phases, bus, and power supply. -
Page 6: Specifications
2.4 Name Regulation The name regulation of Kelly BLDC motor controllers KLS 72 50D KLS:Kelly BLDC motor controller based on sinusoidal waveform which is supposed to work with BLDC motor with three hall sensors. 72:72V batteries 50:The matched motor is 72V 5KW BLDC motor with hall sensors. -
Page 7: Chapter 3 Wiring And Installation
Kelly KLS-D Brushless Motor Controller User’s Manual V 1.5.02 3.72V model: range of the batteries is 24V-72V. 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. -
Page 8: Connections
Kelly KLS-D Brushless Motor Controller User’s Manual V 1.5.02 3.2 Connections 3.2.1 Pin definition of KLS-D Controller waterproof connector Figure 2: 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 . - Page 9 Kelly KLS-D Brushless Motor Controller User’s Manual V 1.5.02 (34)CAN-L:Dark Gray 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.
- Page 10 Kelly KLS-D Brushless Motor Controller User’s Manual V 1.5.02 3.2.2 Standard Wiring of KLS-D Controller Figure 3: KLS-D controller standard wiring (Battery voltage can be used for controller supply)
- Page 11 Kelly KLS-D Brushless Motor Controller User’s Manual V 1.5.02 3.2.3 Optional wiring of KLS-D controller The 12V input signal of the pin supplies the second braking function of the controller. Figure 4: Wiring of brake switch(12V): 12V is provided by external source.
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Page 12: Installation Check List
Kelly KLS-D Brushless Motor Controller User’s Manual V 1.5.02 3.2.4 Communication Port A 4pin connector to RS232 port is provided to communicate with host computer for calibration and configuration. Figure 7: RS232 Interface on 4pin connector to RS232 converter Figure 8：SM-4P connector for communication interface on KLS-D controller 3.3 Installation Check List... -
Page 13: Chapter 4 Programmable Parameters
Kelly KLS-D Brushless Motor Controller User’s Manual V 1.5.02 • With the brake switch open, 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. - Page 14 (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.
- Page 15 Kelly KLS-D Brushless Motor Controller User’s Manual V 1.5.02 (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.
- Page 16 Kelly KLS-D Brushless Motor Controller User’s Manual V 1.5.02 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.
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Page 17: Step 2
Kelly KLS-D Brushless Motor Controller User’s Manual V 1.5.02 Forward Forward Disable Disable 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. -
Page 18: Step 3
Kelly KLS-D Brushless Motor Controller User’s Manual V 1.5.02 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 130°C. -
Page 19: Chapter 5 Maintenance
Kelly KLS-D Brushless Motor Controller User’s Manual V 1.5.02 (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. -
Page 20: Configuration
Identification angle operation. • Use a straight through RS232 cable or USB converter provided by Kelly to connect to a host computer. Provide >+18V to PWR（for a 24V controller, provide >+8V）. Wire power supply return(supply negative) to any RTN pin. -
Page 21: Table 1: Error Codes
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 incorrect wiring. 3. Controller is damaged. Contact Kelly about a warranty repair. Over temperature ¤¤... -
Page 22: Contact Us
Kelly KLS-D Brushless Motor Controller User’s Manual V 1.5.02 or short-circuit fault. 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. Regen or Start-up ¤¤¤¤...