Kelly KLS6045H User Manual
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Kelly KLS6045H User Manual

Sinusoidal brushless permanent magnet motor controllers
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Kelly KLS-H Sinusoidal Brushless Permanent Magnet Motor Controller User's Manual
Sinusoidal Brushless Permanent Magnet Motor Controllers
KLS6045H
KLS6045HC
Kelly KLS-H
User's Manual
Devices Supported
KLS7222H
KLS7222HC
KLS7230H
KLS7230HC
KLS7275H
KLS7275HC
KLS8422H
KLS8422HC
KLS8430H
KLS8430HC
KLS84501-8080H
KLS84601-8080H
V1.2
KLS96401-8080H
KLS96501-8080H
Rev.1.2
Apr. 2023

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Summary of Contents for Kelly KLS6045H

  • Page 1 Kelly KLS-H Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V1.2 Kelly KLS-H Sinusoidal Brushless Permanent Magnet Motor Controllers User’s Manual Devices Supported KLS6045H KLS7222H KLS8422H KLS96401-8080H KLS6045HC KLS7222HC KLS8422HC KLS96501-8080H KLS7230H KLS8430H KLS7230HC KLS8430HC KLS7275H KLS84501-8080H KLS7275HC KLS84601-8080H Rev.1.2...

  • Page 2: Table Of Contents

    Kelly KLS-H Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V1.2 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. But KLS-8080H model is only IP54 rating.

  • Page 4: Chapter 2 Features And Specifications

    Kelly KLS-H Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.2 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 1.2 (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. (24)Can support three speed function on the latest version.

  • Page 6: Specifications

    Kelly KLS-H Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.2 2.3 Specifications •Frequency of Operation: 10KHz or 20KHz. •Standby Battery Current: < 0.5mA. •5V or 12V Sensor Supply Current: 40mA. •The PWR can be 96V batteries for KLS96xxx-8080H model. So All KLS-H and KLS-8080H model are non isolated type controllers.

  • Page 7: Name Regulation

    The name regulation of Kelly BLDC motor controllers KLS7230H 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 8 Kelly KLS-H Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.2 To ensure full rated output power, the controller should be fastened to a clean, flat metal surface with four screws. Applying silicon grease or some other thermal conductive material to contact surface will enhance thermal performance.
  • Page 9 Kelly KLS-H Brushless Motor Controller User’s Manual V 1.2 Figure 2: KLS7245H KLS7245HC mounting holes’ dimensions (dimensions in millimeters)
  • Page 10 Kelly KLS-H Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.2 Figure 3: KLS7275H KLS7275HC mounting holes’ dimensions (dimensions in millimeters)
  • Page 11 Kelly KLS-H Brushless Motor Controller User’s Manual V 1.2 KLS84501-8080H KLS84601-8080H KLS96401-8080H KLS96501-8080H Figure 4: mounting holes’ dimensions (dimensions in millimeters)

  • Page 12: Connections

    Kelly KLS-H Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.2 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 1.2 （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 Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.2 3.2.2 Standard Wiring of KLS-H Controller Figure 6: 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 1.2 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.

  • Page 16: Installation Check List

    Kelly KLS-H Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.2 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...

  • Page 17: Chapter 4 Programmable Parameters

    Kelly KLS-H Brushless Motor Controller User’s Manual V 1.2 • 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 by default.
  • Page 19 Kelly KLS-H Brushless Motor Controller User’s Manual V 1.2 always in the range of 0.5V to 4.5V. But it doesn't make any differences if you choose 0-5V or 3-wire pot for the throttle type. That is to say, these two settings are only useful for hall active throttle or pedal when you chose throttle type at 2.
  • Page 20 Kelly KLS-H Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.2 20~100 By default, it is set at 100% (18)PWM Frequency: Frequency of PWM operation. Unit: KHz Functional description:20KHz is better for hub motor with strict quiet control. Suggestion: Set according to the practical situation, factory default is 20KHz.Please don’t set it 20KHz above.
  • Page 21 Kelly KLS-H Brushless Motor Controller User’s Manual V 1.2 Suggestion: Set according to the practical situation, factory default is Disable. (20-A)Three Gears Switch Value range: Enable and Disable Functional description: If enabled, the Forward switch will be activated. Please see figure 4.1.

  • Page 22: Step 2

    Kelly KLS-H Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.2 If there is no foot switch signal, the controller will ignore the throttle signal. Suggestion: Set according to the practical situation, factory default is Disable. (26)Cruise Control: Value range: Enable and Disable If enable, if you hold throttle at certain position about 3-4 seconds, the controller will get into Cruise control.
  • Page 23 Kelly KLS-H Brushless Motor Controller User’s Manual V 1.2 (2)NTL Brk %: NTL Braking Percent, the percent of Neutral Braking in max braking. Range: 0~50 Only useful when you enable Three gears switch in user program. The regen will happen when you turn F-N-R switch from Forward or backward to Neutral position.

  • Page 24: How To Use Identification Angle Operation Function

    Kelly KLS-H Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.2 Dir brake item in user program. It will help the motor change the direction of motor quickly after you shift throttle from 0V to 5V,or from 5V to 0V.
  • Page 25 Kelly KLS-H Brushless Motor Controller User’s Manual V 1.2 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...
  • Page 26 Kelly KLS-H Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.2 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. 3,Please download the controller user program from our website for free.
  • Page 27 Kelly KLS-H Brushless Motor Controller User’s Manual V 1.2 message in monitor screen of user program for KLS-D/H controller also. 9,Please turn off the power supply again. Please wait about a few seconds to turn on the power supply one more time.

  • Page 28: 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 29 Kelly KLS-H Brushless Motor Controller User’s Manual V 1.2 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 30 Kelly KLS-H Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.2 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 31: Contact Us

    Kelly KLS-H Brushless Motor Controller User’s Manual V 1.2 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:

Kls-hKls7222hKls8422hKls96401-8080hKls6045hcKls7222hc ... Show all

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