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Summary of Contents for Kelly KLS-S
- Page 1 Kelly KLS-S Brushless Motor Controller User’s Manual V1.9 Kelly KLS-S Brushless Motor Controller User’s Manual Devices Supported: KLS4812S KLS7212S KLS6018S KLS7230S KLS6025S KLS7218S KLS6030S KLS7240S Rev1.9 Feb.2016...
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Page 2: Table Of Contents
Kelly KLS-S Brushless Motor Controller User’s Manual V1.9 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 Small 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-S Brushless Motor Controller User’s Manual V1.9 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. -
Page 5: Features
Kelly KLS-S Brushless Motor Controller User’s Manual V1.9 Caution! The regen is not a safe function.Usually you may use the mechanical brake. 2.2 Features 1) Intelligence with powerful microprocessor. 2) Synchronous rectification, ultra low drop, fast SVPWM and FOC to achieve very high efficiency. -
Page 6: Specifications
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 S:Mini case for the controller... -
Page 7: Chapter 3 Wiring And Installation
Kelly KLS-S Brushless Motor Controller User’s Manual V1.9 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 Kelly KLS-S Brushless Motor Controller User’s Manual V1.9 mounting holes’ dimensions (dimensions in millimeters) Figure 2:KLS6018S...
- Page 9 Kelly KLS-S Brushless Motor Controller User’s Manual V1.9 mounting holes’ dimensions (dimensions in millimeters) Figure 3:KLS7218S...
- Page 10 Kelly KLS-S Brushless Motor Controller User’s Manual V1.9 mounting holes’ dimensions (dimensions in millimeters) Figure 4:KLS6025S...
- Page 11 Kelly KLS-S Brushless Motor Controller User’s Manual V1.9 mounting holes’ dimensions (dimensions in millimeters) Figure 5:KLS6030S KLS7230S...
- Page 12 Kelly KLS-S Brushless Motor Controller User’s Manual V1.9 mounting holes’ dimensions (dimensions in millimeters) Figure 6:KLS7240S...
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Page 13: Connections
Kelly KLS-S Brushless Motor Controller User’s Manual V1.9 3.2 Connections 3.2.1 Pin definition of KLS-S Controller waterproof connector Figure 7: 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. - Page 14 Kelly KLS-S Brushless Motor Controller User’s Manual V1.9 DJ7091Y-2.3-21 Pin Definition (15) Micro_SW: Throttle switch input. Gray (3) Throttle: Throttle analog input, 0-5V. Green (1) Temp: Motor temperature sensor input. Raddle. (20) RTN: Signal return. Black (8) Meter: Copy signal of hall sensors. Dark Gray (4) 5V: 5V supply output, <40mA.
- Page 15 Kelly KLS-S Brushless Motor Controller User’s Manual V1.9 3.2.2 Wiring of KLS-S Controller 3.2.2.1 Standard wiring of KLS-S controller Figure 8: KLS-S controller standard wiring (Battery voltage can be used for controller supply)
- Page 16 The 12V input signal of the pin supplies the second braking function of the controller. Figure 9: Wiring of brake switch(12V): 12V is provided by external source. Figure 10: Wiring of brake switch(12V): 12V is provided by KLS-S controller on pin11 Figure 11: Wiring diagram for motor temperature sensor 3.2.3 Communication Port...
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Page 17: Installation Check List
Kelly KLS-S Brushless Motor Controller User’s Manual V1.9 Figure 12: RS232 Interface on 4pin connector to RS232 converter Figure 13：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. -
Page 18: Chapter 4 Programmable Parameters
Kelly KLS-S Brushless Motor Controller User’s Manual V1.9 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. - Page 19 (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 20 Kelly KLS-S Brushless Motor Controller User’s Manual V1.9 (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.
- Page 21 Kelly KLS-S Brushless Motor Controller User’s Manual V1.9 If throttle got effective 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.
- Page 22 Kelly KLS-S Brushless Motor Controller User’s Manual V1.9 Configuration Pin Status Running Forward FWD_SW REV_SW Foot Status Foot Switch Switch (12) (14) (15) Neutral Reverse Enable Disable Forward Neutral Can’t operate Can’t operate Disable Enable Reverse Forward Forward Disable Disable...
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Page 23: Step 2
Kelly KLS-S Brushless Motor Controller User’s Manual V1.9 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. -
Page 24: Step 3
Kelly KLS-S Brushless Motor Controller User’s Manual V1.9 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 25: Chapter 5 Maintenance
Kelly KLS-S Brushless Motor Controller User’s Manual V1.9 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. - Page 26 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 27 Kelly KLS-S Brushless Motor Controller User’s Manual V1.9 Red LED Codes Code Explanation Solution Automatic error ¤ ¤ 1. Wrong wiring of motor phase line or hall. identification Please suspend the motor when enable Auto-Identify function. Over voltage error ¤...
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Page 28: Contact Us
Kelly KLS-S Brushless Motor Controller User’s Manual V1.9 2.Incorrect wiring. 3.Speed sensor is damaged or defective.Or feedback signal is erratic. Reserved ¤¤¤¤ ¤ Reserved 4, 2 ¤¤¤¤ ¤¤ Motor 4, 3 ¤¤¤¤ ¤¤¤ Motor temperature has exceeded the configured over-temperature maximum.