Kelly KLS-H User Manual
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Kelly KLS-H User Manual

Brushless motor controller
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Brushless Motor Controller User's Manual
Kelly KLS-H
Kelly KLS-H Brushless Motor
Controller User's Manual
KLS6022H
KLS7218H
KLS7245H
KLS8415H
KLS72501-8080H
KLS96301-8080H
KLS96601-8080H
Devices Supported:
KLS6030H
KLS7222H
KLS7250H
KLS8422H
KLS72601-8080H
KLS96401-8080H
KLS7215H
KLS7230H
KLS7275H
KLS8430H
KLS72701-8080H
KLS96501-8080H
V1.10

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  • Page 1 Brushless Motor Controller User’s Manual Kelly KLS-H V1.10 Kelly KLS-H Brushless Motor Controller User’s Manual Devices Supported: KLS6022H KLS6030H KLS7215H KLS7218H KLS7222H KLS7230H KLS7245H KLS7250H KLS7275H KLS8415H KLS8422H KLS8430H KLS72501-8080H KLS72601-8080H KLS72701-8080H KLS96301-8080H KLS96401-8080H KLS96501-8080H KLS96601-8080H...
  • Page 2 Brushless Motor Controller User’s Manual Kelly KLS-H V1.10 Rev.1.10 Jun.2017...

  • Page 4: Table Of Contents

    Contents 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 ....................... 5 Chapter 3 Wiring and Installation ..................6 3.1 Mounting the Controller .....................

  • Page 5: Chapter 1 Introduction

    Android Tablet as display device.Customers can connect the KLS controller to Android App in Android Phone if they order Bluetooth converter from Kelly Controls. KLS-H has a friendly I/O terminals for customers to hook up the batteries and motor easily.

  • Page 6: Chapter 2 Features And Specifications

    (20) KLS-H controller included the fuse on the case.Not shunt is attached. (21) Cruise control.Only can be activated in forward direction. (22) KLS-H can support Broadcast type CAN Bus function.It is 250Kbps.CAN bus is not included in KLS-H controller by default.CAN bus is only an optional function for KLS-H.

  • Page 7: Features

    22) Support motors with any number of poles. 23) Up to 70,000 electric RPM standard. (Electric RPM = mechanical RPM * motor pole pairs;Motor pole pairs=Motor poles/2). 24) KLS-H:Dust and water protected under sealed condition,IP66 25) KLS-8080H.The protection rating is IP54.

  • Page 8: Specifications

    BLDC motor with three hall sensors.All KLS controllers can do regen brake function by default. 72:72V batteries. H:The motor controller included a plastic cover with a fuse.And KLS-H is IP66 rating without filling the silica gel by default.But KLS-8080H is IP54 rating. C:BroadCast type CAN bus protocol.

  • Page 9: Chapter 3 Wiring And Installation

    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. 3.84V model: range of the batteries voltage is 18V-105V. 4.96V model: range of the batteries voltage is 18V-120V Chapter 3 Wiring and Installation 3.1 Mounting the Controller...
  • Page 10 mounting holes’ dimensions Figure 1: KLS7215H KLS7218H KLS6022H,KLS6030H,KLS7230H (dimensions in millimeters)
  • Page 11 mounting holes’ dimensions (dimensions in millimeters) Figure 2: KLS7245H...
  • Page 12 mounting holes’ dimensions (dimensions in millimeters) Figure 3: KLS7250H...
  • Page 13 mounting holes’ dimensions (dimensions in millimeters) Figure 4: KLS7275H...
  • Page 14 mounting holes’ dimensions (dimensions in Figure 5: KLS72xxx-8080H KLS96xxx-8080H millimeters)

  • Page 15: Connections

    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. 3,Boost and Brake analog regeneration mode used the same pin as pin2.
  • Page 16 (9) Relay: Main contactor driver. 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 (1) Temp: Motor temperature sensor input. Raddle.
  • Page 17 3.2.2 Standard Wiring of KLS-HC Controller Figure 6: KLS-H controller standard wiring (Battery voltage can be used for controller supply)
  • Page 18 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 7: Wiring of brake switch(12V): 12V is provided by external source. Figure 8: Wiring of brake switch(12V): 12V is provided by KLS-D controller on pin11 Figure 9: Wiring diagram for motor temperature sensor NOTE:The motor temperature sensor and brake switch used the different I/O port on latest...

  • Page 19: Installation Check List

    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 Before operating the vehicle, complete the following checkout procedure. Use buzzer code as a reference as listed in Table 1.

  • Page 20: Chapter 4 Programmable Parameters

    • 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 21: Step 1

    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 18~105 Controller will not operate when battery voltage is near the value so as to protect battery. Suggestion: Set according to the practical situation.By default,it is set at 18V.
  • Page 22 (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 23 (14)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 1000Hz above. (15)Max Speed: Max Speed [rpm]. Range: 0~15000 By default,it is set at 4000.Software version 0109 can support 15000RPM settings in user program.
  • Page 24 0-5V throttle for the controller.If you don't choose the joystick,you operated the throttle in this way.The motor speed will increase when the throttle is from 0V 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 0V is backward.

  • Page 25: Step 2

    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. If disabled,the controller can provide brake sensor regen mode on the same pin as pin2.In simple,boost and brake analog regen used the same pin as pin2.

  • Page 26: Step 3

    High Temp Cut Out °C: Motor High Temp Cut Out, nominal value 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 4.3 Step 3 (1) RLS_TPS Brk %: RLS TPS Braking Percent, the percent of Releasing Pedal BRK in max braking.

  • Page 27: How To Use Identification Angle Operation Function

    (8) Brake Analog regen Brk%:It is used to adjust the max regen percentage of brake variable regen mode. This regen mode doesn't need brake switch to support any more for KLS controller. (8) Torque Speed KP: Speed Percent Kp in Torque Mode. Range: 0~10000 Factory set is 3000 Torque Speed KI: Speed Integral Ki in Torque Mode.
  • Page 28 2,Please connect the controller to user program by using an USB to RS232 cable and SM-4A DB9(RS232) Converter.
  • Page 29 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 Bluetooth converter for programming the controller.
  • Page 30 Please check whether the Identification Angle item is at 85 or not.It is correct if identification angle item is at 85. 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.Please turn off the power supply.

  • Page 31: Chapter 5 Maintenance

    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. 13,If the constant beep sound lasts above 5 minters and there are other error 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.

  • Page 32: Cleaning

    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 33 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. 4. If this error code occurs,the relay function on plin9...
  • Page 34 Over temperature The controller temperature has exceeded 100℃. The ¤¤ ¤¤¤ controller will be stopped but will restart when temperature falls below 80℃. Throttle signal is higher than the preset ‘dead zone’ at Throttle error at ¤¤ ¤¤¤¤ power-up Power On. Fault clears when throttle is released. ¤¤¤...
  • Page 35 For more Information contact: Frikkie Combrink +27 73 070 8545 sales@zmsa.co.za Jo Smith +27 82 552 3917 jo@zmsa.co.,za +27 11 240 6900 info@zmsa.co.za www.zmsa.co.za...

This manual is also suitable for:

Kls6022hKls6030hKls7215hKls7218hKls7222hKls7230h ... Show all

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