Kelly KHS32020II User Manual
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Kelly KHS32020II User Manual

Khs high voltage sine wave brushless dc motor controller
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Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User's Manual
Sine Wave Brushless DC Motor
Kelly KHS High Voltage
Controller User's Manual
KHS32020II
KHS36020II
Models:
KHS32020IIPS
KHS36020IIPS
V 1.10
Rev.1.10
July, 2022

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Summary of Contents for Kelly KHS32020II

  • Page 1 Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual Models: KHS32020II KHS32020IIPS KHS36020II KHS36020IIPS Rev.1.10 July, 2022...

  • Page 2: Table Of Contents

    Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 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 ....................

  • Page 3: Chapter 1 Introduction

    1 Introduction 1.1 Overview This manual introduces the Kelly KHS high voltage sine wave brushless DC 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.

  • Page 4: Chapter 2 Features And Specifications

    Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 Note: Anyway please first to do identification angle operation. And please don't try to connect the controller to user program while the motor is still running, let alone change the setting in user program or Android App.

  • Page 5: Features

    Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 (15) Configurable motor over-temperature detection and protection with the recommended thermistor KTY84-130/150 or KTY83-122. (16) 3 hall position sensor inputs. Open collector, pull up provided. Sin/Cosin Speed sensors inputs.

  • Page 6: Specifications

    Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 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.

  • Page 7: Name Regulation

    The name regulation of Kelly KHS motor controllers KHS-I/IPS KHS: Kelly high voltage BLDC motor controller based on sine wave. KHS-I is supposed to work with brushless motor with three hall sensors. KHS-IPS can work with Sin/Cosin speed sensors. There are +5V, Sin,Cosin and GND I/O ports for brushless motor with Sin/Cosin speed sensors.
  • Page 8 Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 KHS controller Mounting Holes‟ Dimensions (dimensions in millimeters) Figure1:...

  • Page 9: Connections

    Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 3.2 Connections 3.2.1 Pin definition of the 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 10 Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 (33)CAN-H:Greenish(Optional function) (7) PWR: Controller power supply (input). Pink (34)CAN-L:Brownish(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 11 Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 3.2.2 Simple Wiring of the Controller’s Auto Identification Figure 4: KHS-I Controller Simple Wiring (Auto Identification)
  • Page 12 Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 Figure 5: KHS-IPS Controller Simple Wiring (Auto Identification)
  • Page 13 Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 3.2.3 Standard Wiring of the Controller Figure 6: KHS-I Controller Standard Wiring (FNR) Figure 7: KHS-I Controller Standard Wiring (3 speeds)
  • Page 14 Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 Figure 8: KHS-IPS Controller Standard Wiring (FNR) Figure 9: KHS-IPS Controller Standard Wiring (3 speeds)
  • Page 15 Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 3.2.4 Optional wiring of the controller The 12V input signal of the pin supplies the second braking function of the controller. Figure 10: Wiring of brake switch (12V): 12V is provided by external source.

  • Page 16: Installation Check List

    Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 3.2.5 Communication Port A 4pin connector to RS232 port is provided to communicate with host computer for calibration and configuration. Figure 13: RS232 Interface on 4pin connector to RS232 converter Figure 14：SM-4P connector for communication interface on the controller...

  • Page 17: Chapter 4 Programmable Parameters

    Kelly KHS High Voltage Sine Wave Brushless DC 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: Step 1

    Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 4.1 Step 1 (1)Low Volt: The min voltage of reporting this fault - Range 180~450 Controller will not operate when battery voltage is near the value so as to protect battery.
  • 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 KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 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.
  • Page 21 Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 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.

  • Page 22: Step 2

    Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 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 23: Step 3

    Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 (3)Speed Sensor Type: Speed Sensor Type, 2:Hal, 3:Resolver(Reservation), 4:Line Hall. Range: 2 or 4 Different sensors type. By defualt, it is set at 2 If you have a motor with 5V,Sin/Cosin, GND speed sensors, please choose it at 4.And please inquire the KHS-IPS model before ordering.KHS-IPS can not support Resolver sensor type for...
  • Page 24 Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 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: How To Use Identification Angle Operation For Khs-I Controller

    Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 value respectively. (10) Compensation Per% Tried to increase the current usage during Anti-Slip operation. (11)Torque Speed Kp:3000 Torque Speed Ki:80 Speed Err Limit:1000 These parameters are used for PID adjustment. If the acceleration is too aggressive, please reduce these three parameters at the same time, vice versa.
  • Page 26 Kelly KHS High Voltage Sine Wave Brushless DC 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 27 Kelly KHS High Voltage Sine Wave Brushless DC 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: Customers can buy our Bluetooth converter to connect the controller to Android Phone.
  • Page 28 Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 Pin7/Pin6.Please try to open the user program in your computer or other devices. Then you may try to click Read button in user program or App. You will see the first picture of user program.
  • Page 29 Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 9,Please turn off the power supply again. Please wait about a few seconds to turn on the power supply one more time. 10,Please try to connect the controller to user program again. You will see 85 in the identification angle item.

  • Page 30: How To Use Identification Angle Operation For Khs-Ips Controller

    Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 4.5 How to use Identification angle operation for KHS-IPS controller We must do Identification angle operation before running motor for all KHS controllers. The Identification angle operation can be done in PC program or Android App(Tablet or Cell Phone).
  • Page 31 Kelly KHS High Voltage Sine Wave Brushless DC 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 32 Kelly KHS High Voltage Sine Wave Brushless DC 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.
  • Page 33 Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 www.kellycontroller.com/support.php Please install the user program in your computer, Tablet or Phone. 4.1, Please turn on the key switch so that the controller can get power supply from B+/B- and Pin7/Pin6.Please try to open the user program in your computer or other devices.
  • Page 34 Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 Usually we just need to configure two parameters in user program according to the specification of Sin/Cosin speed sensor. Please click Motor button in the user program.
  • Page 35 Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 So output range of Sin/Cosin speed sensor is 3-1.1V=1.9V to 3+1.1V=4.1V.(1.9V-4.1V). We set the Line hall high err at 972.It is about 4.75V.The line hall low err at 50.It is about 0.25V.
  • Page 36 Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 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 37: Chapter 5 Maintenance

    Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 connect a lower volt such as 24V-72V to + terminal, customers must set 0V for pre-charge voltage in user program before doing controller‟s auto_Identification. When the identification angle operation is finished successfully, customers need to set up the pre-charge voltage and pre-charge time in the user program.

  • Page 38: 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 39: Led Error Codes

    Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 Table 1: ERROR CODES LED Error 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.

  • Page 40: Contact Us

    Kelly KHS High Voltage Sine Wave Brushless DC Motor Controller User’s Manual V 1.10 ¤¤¤ ¤ Reserved 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.

This manual is also suitable for:

Khs32020iipsKhs36020iiKhs36020iips

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