Kelly KLS-N Series User Manual
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Kelly KLS-N Series User Manual

Sinusoidal brushless permanent magnet motor controller
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Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User's Manual
Kelly KLS-N Sinusoidal Brushless
Permanent Magnet Motor Controller
KLS2412ND
KLS4812N
KLS4850N
KLS7212ND
KLS7218N
KLS7250N
User's Manual
Devices Supported:
KLS2412N
KLS4818N
KLS4875NC KLS48100NC KLS48120NC
KLS7212N
KLS7215ND
KLS7222N
KLS7275NC KLS72100NC KLS72120NC
KLS2418N
KLS4812ND
KLS4830N
KLS4840N
KLS7215N
KLS7230N
KLS7240N
V2.9
Rev. 2.9
Feb. 2023

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Summary of Contents for Kelly KLS-N Series

  • Page 1 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual Devices Supported: KLS2412ND KLS2412N KLS2418N KLS4812ND KLS4812N KLS4818N KLS4830N KLS4840N KLS4850N KLS4875NC KLS48100NC KLS48120NC KLS7212ND KLS7212N KLS7215ND KLS7215N KLS7218N...

  • Page 2: Table Of Contents

    Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 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

    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.

  • Page 4: Chapter 2 Features And Specifications

    Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 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-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 included in KLS-N controller by default.CAN bus is only an optional function for KLS-N. (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 KLS2412ND 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-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 KLS7230N 48-72V 40-86V 280A KLS7240N 48-72V 40-86V 320A 100A KLS7250N 48-72V 40-86V 360A 120A Note: *depends on conductive heat sink Kelly KLS-N - Sinusoidal Brushless Permanent Magnet Motor Controller...
  • Page 8 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 Figure 1: KLS2412ND KLS4812ND KLS7212ND KLS7215ND mounting holes’ dimensions (dimensions in millimeters) B+,B-,U,V,W:M5 Bolts Figure 2: KLS2412N KLS4812N KLS7212N KLS7215N mounting holes’ dimensions (dimensions in millimeters) B+,B-,U,V,W:M5 Bolts...
  • Page 9 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 Figure 3: KLS2418N KLS4818N KLS7218N KLS7222N mounting holes’ dimensions (dimensions in millimeters)
  • Page 10 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 Figure 4: KLS4830N KLS7230N mounting holes’ dimensions (dimensions in millimeters)
  • Page 11 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 Figure 5: KLS4840N KLS7240N mounting holes’ dimensions (dimensions in millimeters)
  • Page 12 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 Figure 6: KLS4850N KLS7250N mounting holes’ dimensions (dimensions in millimeters)
  • Page 13 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 Figure7: KLS4875NC KLS7275NC KLS48100NC KLS72100NC KLS48120NC KLS72120NC mounting holes’ dimensions (dimensions in millimeters) +/B+/B-/U/V/W:M8...

  • Page 14: Connections

    Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 3.2 Connections 3.2.1 Pin definition of KLS-N Controller waterproof connector Figure 8: 1，The switch signal is valid to 12V 2，12V only can be used for LED or switch signals.
  • Page 15 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 (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. Black (8) Meter: Copy signal of hall sensors.
  • Page 16 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 3.2.2 Standard Wiring of KLS-N Controller Figure 9: KLS-N controller standard wiring (Battery voltage can be used for controller supply) 3.2.3 Optional wiring of KLS-N controller The 12V input signal of the pin supplies the second braking function of the controller.
  • Page 17 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 Figure 11: Wiring of brake switch(12V): 12V is provided by KLS-N controller on pin11 Figure 12: Wiring diagram for motor temperature sensor NOTE: KLS controller can support KTY84-130/150 and KTY83-122 thermistors.

  • Page 18: Installation Check List

    Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 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. Caution: • Put the vehicle up on blocks to get the drive wheels off the ground before beginning these tests.

  • Page 19: Chapter 4 Programmable Parameters

    Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 Chapter 4 Programmable Parameters KLS Configuration program allow users to set parameters according to the vehicle actual working environment so as to be at its best. The default parameters of the controller are not recommended for all applications. Make sure set the proper parameters before making any test to avoid danger.
  • Page 20 (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 21 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 (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 22 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 pin22 and pin12 are disconnected from pin11,the controller is driving with medium speed mode. Three speed: This item is used to enable or disable three speed function. By default, it is at 0 0:Three speed function is disabled.1:Two speed function.2:Three speed function is enabled.
  • Page 23 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 Please note the common throttle will spring back to original position if you release the throttle. Suggestion: factory default is Disable. (23)Three Gears switch: It is used for function of F-N-R control.

  • Page 24: Step 2

    Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 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.

  • Page 25: Step 3

    Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 If you have a motor with 5V,Sin/Cosin, GND speed sensors, please choose it at 4.And please inquire the KLS-8080IPS model before ordering. (4)Resolver Poles: Resolver Poles, The pair pole number*2. Range: 2~32 It is only used for the Resolver sensor type.
  • Page 26 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 (6)Brake Rls Time: Brake Release Time, the time of Brake Torque from max to 0, accuracy 0.1s. Range: 1~250 Factory set is 1 (7)BRK_SW Brk %: BRK_SW Braking Percent, the percent of BRK_SW in max braking. Range: 0~50 The brake switch regen mode.

  • Page 27: How To Use Identification Angle Operation Function

    Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 These parameters are used for PID adjustment. If the acceleration is too aggressive, please reduce these three parameters at the same time, vice versa. Please change the Torque Speed Kp every 1000 units,Torque speed Ki every 100 units and Speed Err limit every 500 units.
  • Page 28 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 2,Please connect the controller to user program by using an USB to RS232 cable and SM-4A DB9(RS232) Converter.
  • Page 29 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 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 30 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 3,Please download the controller user program from our website for free. www.kellycontroller.com/support.php Please install the user program in your computer, Tablet or Phone. 4,Please turn on the key switch so that the controller can get power supply from B+/B- and Pin7.Please try to open the user program in your computer or other devices.
  • Page 31 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 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 32: 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 33 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 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 34 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 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.

  • Page 35: Contact Us

    Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9 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:

Kls2412ndKls2412nKls2418nKls4812ndKls4812nKls4818n ... Show all

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