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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
User's Manual
Devices Supported:
KLS2412N
KLS2445N
KLS2413N
KLS2412NX
KLS2414N
KLS6018N
KLS2415N
KLS6030N
KLS2418N
KLS7212N
KLS2430N
KLS7215N
KLS7218N
KLS7230N
KLS7245N
KLS7250N
KLS7212NX
V2.8
Rev.2.8
Nov. 2022
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Table of Contents
Related Manuals for Kelly KLS2413N
Summary of Contents for Kelly KLS2413N
- Page 1 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.8 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual Devices Supported: KLS2412N KLS2445N KLS7218N KLS2413N KLS2412NX KLS7230N KLS2414N KLS6018N KLS7245N KLS2415N KLS6030N KLS7250N KLS2418N KLS7212N KLS7212NX KLS2430N KLS7215N Rev.2.8...
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Page 2: Table Of Contents
Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.8 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 V2.8 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 V2.8 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 KLS 72 18N 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 V2.8 KLS7218N 40-72 KLS6018N 40-60 KLS7212NX 40-72 KLS6030N 40-60 KLS7230N 40-72 KLS7245N 40-72 KLS7250N 40-72 Chapter 3 Wiring and Installation 3.1 Mounting the Controller The controller can be oriented in any position which should be as clean and dry as possible, and if necessary, shielded with a cover to protect it from water and contaminants. - Page 8 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.8 mounting holes’ dimensions Figure 2: KLS2413N (dimensions in millimeters) B+,B-,U,V,W:M5 Bolts mounting holes’ dimensions Figure 3: KLS2414N (dimensions in millimeters) B+,B-,U,V,W:M5 Bolts...
- Page 9 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.8 mounting holes’ dimensions Figure 4: KLSxx15N (dimensions in millimeters) B+,B-,U,V,W:M5 Bolts mounting holes’ dimensions Figure 5: KLSxx18N (dimensions in millimeters)
- Page 10 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.8 mounting holes’ dimensions Figure 6: KLSxx30N (dimensions in millimeters)
- Page 11 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.8 mounting holes’ dimensions Figure 7: KLSxx45N (dimensions in millimeters)
- Page 12 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.8 mounting holes’ dimensions Figure 8: KLS7250N (dimensions in millimeters)
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Page 13: Connections
Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.8 3.2 Connections 3.2.1 Pin definition of KLS-N Controller waterproof connector Figure 9: 1，The switch signal is valid to 12V 2，12V only can be used for LED or switch signals. - Page 14 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.8 (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 15 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.8 3.2.2 Standard Wiring of KLS-N Controller Figure 10: 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 16 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.8 Figure 12: Wiring of brake switch(12V): 12V is provided by KLS-N controller on pin11 Figure 13: Wiring diagram for motor temperature sensor NOTE: KLS controller can support KTY84-130/150 and KTY83-122 thermistors.
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Page 17: Installation Check List
Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.8 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 18: Chapter 4 Programmable Parameters
Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.8 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 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 KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.8 (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 21 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.8 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 22 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.8 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 23: Step 2
Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.8 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 24: Step 3
Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.8 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 25 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.8 (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 26: How To Use Identification Angle Operation Function
Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.8 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 27 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.8 2,Please connect the controller to user program by using an USB to RS232 cable and SM-4A DB9(RS232) Converter.
- Page 28 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.8 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 29 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.8 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 30 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.8 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 31: 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 32 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.8 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 33 Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.8 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 34: Contact Us
Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.8 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...