Kelly KLS6022H User Manual
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Kelly KLS6022H User Manual

Brushless motor controller
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Kelly KLS-H Brushless Motor Controller User's Manual
Kelly KLS-H Brushless Motor
Controller User's Manual
KLS6022H
KLS7218H
KLS7245H
KLS8415H
KLS72501-8080H
KLS96301-8080H
KLS96601-8080H
Devices Supported:
KLS6030H
KLS7222H
KLS7275H
KLS8422H
KLS72601-8080H
KLS96401-8080H
KLS7215H
KLS7230H
KLS8430H
KLS72701-8080H
KLS96501-8080H
V1.10
Rev.1.1
Jun.2019

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  • Page 1 Kelly KLS-H Brushless Motor Controller User’s Manual V1.10 Kelly KLS-H Brushless Motor Controller User’s Manual Devices Supported: KLS6022H KLS6030H KLS7215H KLS7218H KLS7222H KLS7230H KLS7245H KLS7275H KLS8415H KLS8422H KLS8430H KLS72501-8080H KLS72601-8080H KLS72701-8080H KLS96301-8080H KLS96401-8080H KLS96501-8080H KLS96601-8080H Rev.1.1 Jun.2019...

  • Page 2: Table Of Contents

    Kelly KLS-H Brushless Motor Controller User’s Manual V1.10 Contents Contents ......................1 Chapter 1 Introduction ................. 2 1.1 Overview........................ 2 Chapter 2 Features and Specifications ............3 2.1 General functions ....................3 2.2 Features ........................ 4 2.3 Specifications ......................5 2.4 Name Regulation ....................

  • 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.But KLS-8080H model is only IP54 rating.

  • Page 4: Chapter 2 Features And Specifications

    Kelly KLS-H Brushless Motor Controller User’s Manual V 1.10 Chapter 2 Features and Specifications 2.1 General functions (1) Extended fault detection and protection. Customers can read the error message in PC software or Android APP 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-H Brushless Motor Controller User’s Manual V 1.10 included in KLS-H controller by default.CAN bus is only an optional function for KLS-H. CAN ID can be changed in the latest user program also. (23)Bluetooth function.Required a small Bluetooth converter which needs to be purchased in addition from our website.This small converter is only useful for KLS controller.

  • Page 6: Specifications

    The name regulation of Kelly BLDC motor controllers KLS 72 30H KLS:Kelly BLDC motor controller based on sinusoidal waveform which is supposed to work with BLDC motor with three hall sensors.All KLS controllers can do regen brake function by default.

  • Page 7: Chapter 3 Wiring And Installation

    Kelly KLS-H Brushless Motor Controller User’s Manual V 1.10 KLS8430H 24-84 KLS72501-8080H 24-72 KLS72601-8080H 24-72 KLS72701-8080H 24-72 KLS96301-8080H 24-96 KLS96401-8080H 24-96 KLS96501-8080H 24-96 KLS96601-8080H 24-96 1.60V model: range of the batteries voltage is 18V-80V. 2.72V model: range of the batteries voltage is 18V-90V.
  • Page 8 Kelly KLS-H Brushless Motor Controller User’s Manual V 1.10 mounting holes’ dimensions Figure 1: KLS7215H KLS7218H KLS6022H,KLS6030H,KLS7230H (dimensions in millimeters)
  • Page 9 Kelly KLS-H Brushless Motor Controller User’s Manual V 1.10 mounting holes’ dimensions (dimensions in millimeters) Figure 2: KLS7245H...
  • Page 10 Kelly KLS-H Brushless Motor Controller User’s Manual V 1.10 mounting holes’ dimensions (dimensions in millimeters) Figure 3: KLS7275H...
  • Page 11 Kelly KLS-H Brushless Motor Controller User’s Manual V 1.10 mounting holes’ dimensions (dimensions in Figure 4: KLS72xxx-8080H KLS96xxx-8080H millimeters)

  • Page 12: Connections

    Kelly KLS-H Brushless Motor Controller User’s Manual V 1.10 3.2 Connections 3.2.1 Pin definition of KLS-H Controller 1,The switch signal is valid to 12V on pin11 2,12V capacity is low.This 12V only can be used for LED or switch signals.
  • Page 13 Kelly KLS-H Brushless Motor Controller User’s Manual V 1.10 （22）ECO: Low speed input switch function. Blue (33)CAN-H:Green(Optional function) (7) PWR: Controller power supply (input). Pink (34)CAN-L:Dark Gray(Optional function) DJ7091Y-2.3-21 Pin Definition (15) Micro_SW: Throttle switch input. Gray (3) Throttle: Throttle analog input, 0-5V. Dark Green (20) RTN: Signal return.
  • Page 14 Kelly KLS-H Brushless Motor Controller User’s Manual V 1.10 3.2.2 Standard Wiring of KLS-HC Controller Figure 5: KLS-H controller standard wiring (Battery voltage can be used for controller supply)
  • Page 15 Kelly KLS-H Brushless Motor Controller User’s Manual V 1.10 3.2.3 Optional wiring of KLS-HC controller The 12V input signal of the pin supplies the second braking function of the controller. Figure 6: Wiring of brake switch(12V): 12V is provided by external source.

  • Page 16: Installation Check List

    Kelly KLS-H Brushless Motor Controller User’s Manual V 1.10 3.2.4 Communication Port A 4pin connector to RS232 port is provided to communicate with host computer for calibration and configuration. Figure 10: RS232 Interface on 4pin connector to RS232 converter Figure 11：SM-4P connector for communication interface on KLS-H controller 3.3 Installation Check List...

  • Page 17: Chapter 4 Programmable Parameters

    Kelly KLS-H Brushless Motor Controller User’s Manual V 1.10 • 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.
  • Page 18 (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...
  • Page 19 Kelly KLS-H Brushless Motor Controller User’s Manual V 1.10 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.
  • Page 20 Kelly KLS-H Brushless Motor Controller User’s Manual V 1.10 (16)Max Fwd Speed %: The forward speed of the percentage of maximum speed. Range: 20~100 By default,it is set at 100% (17)Max Rev Speed %: The reverse speed of the percentage of maximum speed. Range: 20~100 By default,it is set at 100% (18)PWM Frequency: Frequency of PWM operation.
  • Page 21 Kelly KLS-H Brushless Motor Controller User’s Manual V 1.10 Suggestion:factory default is Disable. (23)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.

  • Page 22: Step 2

    Kelly KLS-H Brushless Motor Controller User’s Manual V 1.10 function is brake variable regen mode. (25)Foot switch:It 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.

  • Page 23: Step 3

    Kelly KLS-H Brushless Motor Controller User’s Manual V 1.10 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.

  • Page 24: How To Use Identification Angle Operation Function

    Kelly KLS-H Brushless Motor Controller User’s Manual V 1.10 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.
  • Page 25 Kelly KLS-H Brushless Motor Controller User’s Manual V 1.10 2,Please connect the controller to user program by using an USB to RS232 cable and SM-4A DB9(RS232) Converter.
  • Page 26 Kelly KLS-H Brushless Motor Controller User’s Manual V 1.10 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 Android Phone.We don’t have to use SM-4A to DB9(RS232) converter any more when you use...
  • Page 27 Kelly KLS-H Brushless Motor Controller User’s Manual V 1.10 Please check whether the Identification Angle item is at 85 or not.It is correct if identification 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.
  • Page 28 Kelly KLS-H Brushless Motor Controller User’s Manual V 1.10 value is always at 170.That is to say,the controller is still in the processing of identification operation. 12,Please don't try to write 85 in the identification angle or reset the power supply if you don't see any error codes.

  • Page 29: Chapter 5 Maintenance

    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 30 Kelly KLS-H Brushless Motor Controller User’s Manual V 1.10 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.
  • Page 31 Kelly KLS-H Brushless Motor Controller User’s Manual V 1.10 caused by too low a value of Regen or throttle potentiometers or incorrect wiring. 3. Controller is damaged. Contact Kelly about a warranty repair. 4. If this error code occurs,the relay function on plin9 will be deactivated.

  • Page 32: Contact Us

    Kelly KLS-H Brushless Motor Controller User’s Manual V 1.10 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...

This manual is also suitable for:

Kls6030hKls7215hKls7218hKls7222hKls7230hKls7245h ... Show all

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