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Kelly Jaguar series KLS-N Sinusoidal Brushless PM Motor Controller User's Manual
Kelly Puma mini series KLS-N
Modest size & all around Sinusoidal Brushless PM Motor Controllers
MiniKLS2412ND MiniKLS4812ND Mini KLS7220M
MiniKLS2412NV MiniKLS4812NV Mini KLS7225M
MiniKLS2420ND MiniKLS4820ND MiniKLS7215ND
MiniKLS2420NV MiniKLS4820NV MiniKLS7240ND
MiniKLS2425M
MiniKLS2430M
User's Manual
Devices Supported:
MiniKLS4825M
MiniKLS4830M
MiniKLS4840ND
MiniKLS4845ND
MiniKLS745ND
Rev. 2.14
V2.9
Jun. 2023
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Table of Contents
Related Manuals for Kelly Puma mini KLS-N Series
Summary of Contents for Kelly Puma mini KLS-N Series
- Page 1 Kelly Jaguar series KLS-N Sinusoidal Brushless PM Motor Controller User’s Manual V2.9 Kelly Puma mini series KLS-N Modest size & all around Sinusoidal Brushless PM Motor Controllers User’s Manual Devices Supported: MiniKLS2412ND MiniKLS4812ND Mini KLS7220M MiniKLS2412NV MiniKLS4812NV Mini KLS7225M MiniKLS2420ND MiniKLS4820ND MiniKLS7215ND...
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Page 2: Table Of Contents
Kelly Jaguar series KLS-N Sinusoidal Brushless PM 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 Jaguar series KLS-N Sinusoidal Brushless PM 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 Jaguar series KLS-N Sinusoidal Brushless PM 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 Jaguar series KLS-N Sinusoidal Brushless PM Motor Controller User’s Manual V2.9 36-48V 27-60V 400A Up to 200A* Mini KLS4840ND 36-48V 27-60V 450A Up to 225A* Mini KLS4845ND 48-72V 36-86V 200A 75A** Mini KLS7220M 48-72V 36-86V 250A 85A** Mini KLS7225M... - Page 8 Kelly Jaguar series KLS-N Sinusoidal Brushless PM Motor Controller User’s Manual V2.9 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 Jaguar series KLS-N Sinusoidal Brushless PM Motor Controller User’s Manual V2.9 Figure 12:Mini KLS2412NV Mini KLS2420NV Mini KLS4812NV Mini KLS4820NV mounting holes' dimensions (dimensions in millimeters)
- Page 10 Kelly Jaguar series KLS-N Sinusoidal Brushless PM Motor Controller User’s Manual V2.9 Figure 3:Mini KLS2425M Mini KLS2430M Mini KLS4825M Mini KLS4830M Mini KLS7220M Mini KLS7225M mounting holes' dimensions (dimensions in millimeters)
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Page 11: Connections
Kelly Jaguar series KLS-N Sinusoidal Brushless PM Motor Controller User’s Manual V2.9 Figure 1:Mini KLS4840ND Mini KLS4845ND Mini KLS7240ND Mini KLS7245ND mounting holes' dimensions (dimensions in millimeters) 3.2 Connections 3.2.1 Pin definition of KLS-N Controller... - Page 12 Kelly Jaguar series KLS-N Sinusoidal Brushless PM Motor Controller User’s Manual V2.9 waterproof connector Figure 10: 1，The switch signal is valid to 12V 2，12V only can be used for LED or switch signals. 3，Boost and brake analog regen use the same port on pin2.
- Page 13 Kelly Jaguar series KLS-N Sinusoidal Brushless PM Motor Controller User’s Manual V2.9 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. Dark Gray (4) 5V: 5V supply output, <40mA.
- Page 14 Kelly Jaguar series KLS-N Sinusoidal Brushless PM Motor Controller User’s Manual V2.9 Figure 11: 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 15 Kelly Jaguar series KLS-N Sinusoidal Brushless PM Motor Controller User’s Manual V2.9 Figure 13: Wiring of brake switch(12V): 12V is provided by KLS-N controller on pin11 Figure 14: Wiring diagram for motor temperature sensor NOTE: KLS controller can support KTY84-130/150 and KTY83-122 thermistors.
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Page 16: Installation Check List
Kelly Jaguar series KLS-N Sinusoidal Brushless PM 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 17: Chapter 4 Programmable Parameters
Kelly Jaguar series KLS-N Sinusoidal Brushless PM 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 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 Jaguar series KLS-N Sinusoidal Brushless PM 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 20 Kelly Jaguar series KLS-N Sinusoidal Brushless PM 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 21 Kelly Jaguar series KLS-N Sinusoidal Brushless PM 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.
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Page 22: Step 2
Kelly Jaguar series KLS-N Sinusoidal Brushless PM 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 23: Step 3
Kelly Jaguar series KLS-N Sinusoidal Brushless PM 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 24 Kelly Jaguar series KLS-N Sinusoidal Brushless PM 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.
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Page 25: How To Use Identification Angle Operation Function
Kelly Jaguar series KLS-N Sinusoidal Brushless PM 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 26 Kelly Jaguar series KLS-N Sinusoidal Brushless PM 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 27 Kelly Jaguar series KLS-N Sinusoidal Brushless PM 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 28 Kelly Jaguar series KLS-N Sinusoidal Brushless PM 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 29 Kelly Jaguar series KLS-N Sinusoidal Brushless PM 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.
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Page 30: 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 31 Kelly Jaguar series KLS-N Sinusoidal Brushless PM 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 32 Kelly Jaguar series KLS-N Sinusoidal Brushless PM 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.
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Page 33: Contact Us
Kelly Jaguar series KLS-N Sinusoidal Brushless PM 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...
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