Kelly KHS Series User Manual
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Kelly KHS Series User Manual

High voltage opto-isolated sinusoidal motor controllers
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Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User's Manual V 1.25
High Voltage Opto-Isolated Sinusoidal Motor Controllers
Kelly KHS
User's Manual
Devices Supported:
KHS32020I
KHS32030N
KHS32035N
KHS32040N
KHS36020I
KHS36025N
KHS36030N
KHS36035N
KHS32020IPS
KHS32030NPS
KHS32035NPS
KHS32040NPS
KHS36020IPS
KHS36025NPS
KHS36030NPS
KHS36035NPS
Rev.1.24
Feb. 2024

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  • Page 1 Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 Kelly KHS High Voltage Opto-Isolated Sinusoidal Motor Controllers User’s Manual Devices Supported: KHS32020I KHS32020IPS KHS32030N KHS32030NPS KHS32035N KHS32035NPS KHS32040N KHS32040NPS KHS36020I KHS36020IPS KHS36025N KHS36025NPS KHS36030N KHS36030NPS...

  • Page 2: Table Of Contents

    Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 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

    Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 Chapter 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.

  • Page 4: Chapter 2 Features And Specifications

    Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 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 Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 same time on the latest version. Pin 25 is 12V brake switch input port.Pin1 is motor temperature sensor input port. (15) Configurable motor over-temperature detection and protection with the recommended thermistor KTY84-130/150 or KTY83-122.

  • Page 6: Specifications

    Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 18) Controller can do auto_Identification angle for different Sine/Cosine Speed sensors. Can adjust the zero-crossing point and signal amplitude to match different Sine/Cosine speed sensors. 19) Configurable high pedal protection: the controller will not work if high throttle is detected at power on.

  • Page 7: Name Regulation

    Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 2.4 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-N is supposed to work with brushless motor with three hall sensors.
  • Page 8 Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 KHS-I series Figure1: mounting holes’ dimensions (dimensions in millimeters)
  • Page 9 Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 Figure 2: KHS-N series mounting holes’ dimensions (dimensions in millimeters) +/B+/B-/U/V/W:M8...

  • Page 10: Connections

    Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 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，with a total current not exceeding 20mA.
  • Page 11 Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 (22) ECO: Low speed switch input Blue (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.
  • Page 12 Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25...
  • Page 13 Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 3.2.2 Simple Wiring of the Controller’s Auto Identification Figure 4: KHS-I Controller Simple Wiring (Auto Identification)
  • Page 14 Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 Figure 5: KHS-NPS Controller Simple Wiring (Auto Identification)
  • Page 15 Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 3.2.3 Standard Wiring of the Controller Figure 6: KHS-N Controller Standard Wiring (FNR) Figure 7: KHS-N Controller Standard Wiring (3 speeds)
  • Page 16 Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 Figure 8: KHS-NPS Controller Standard Wiring (FNR) Figure 9: KHS-NPS Controller Standard Wiring (3 speeds)
  • Page 17 Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 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 18: Installation Check List

    Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 configuration. Figure 13: RS232 Interface on 4pin connector to RS232 converter Figure 14：SM-4P connector for communication interface on the controller 3.3 Installation Check List Before operating the vehicle, complete the following checkout procedure. Use LED code as a reference as listed in Table 1.

  • Page 19: Chapter 4 Programmable Parameters

    Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 • 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 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 KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 You can adjust the threshold voltage below or above 0.5V.The controller will report the 3.3 code to protect the system according to different types of hall throttle.
  • Page 22 Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 (16)Max Fwd Speed %: The forward speed of the percentage of maximum speed. Range: 20~100 By default, it is set at 100% (17)Max Rev Speed %: The reverse speed of the percentage of maximum speed. Range: 20~100 By default, it is set at 100% Midspeed Forw speed, Midspeed Rev speed, Lowspeed Forw speed and Lowspeed Rev speed.
  • Page 23 Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 Please check the wiring diagram in the manual for F-N-R control. 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.

  • Page 24: Step 2

    Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 Suggestion: Set according to the practical situation, factory default is Disable. (25)Cruise Control: Value range: Enable and Disable If enable, if you hold throttle at certain position about 5 seconds, the controller will get into Cruise control.

  • Page 25: Step 3

    Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 It is only used for the Resolver sensor type which is not accepted by KHS-NPS controller for now. (5)Motor Temp Sensor: Motor Temp Sensor, 0： None,1: KTY84-130 or 150,2:KTY83-122.Range High Temp Cut Out °C: Motor High Temp Cut Out, nominal value 130°C.
  • Page 26 Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 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 27: How To Use Identification Angle Operation For Khs-N Controller

    Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 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. 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 KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 2,Please connect the controller to user program by using an USB to RS232 cable and SM-4A DB9(RS232) Converter.
  • Page 29 Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 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 30 Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 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 31 Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 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: How To Use Identification Angle Operation For Khs-Nps Controller

    Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 4.5 How to use Identification angle operation for KHS-NPS 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 33 Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 2,Please connect the controller to user program by using an USB to RS232 cable and SM-4A DB9(RS232) Converter.
  • Page 34 Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 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 35 Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 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 36 Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 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 37 Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 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 38 Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 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 39: Chapter 5 Maintenance

    Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 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 40: 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 41: Led Error Codes

    Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 Table 1: ERROR CODES LED Error Codes Explanation Solution Automatic error ¤ ¤ 1. Wrong wiring of motor phase line or hall. identification Please suspend the motor when enable Auto-Identify function.

  • Page 42: Contact Us

    Kelly KHS High Voltage Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V 1.25 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:

Khs32020iKhs32020ipsKhs32030nKhs32030npsKhs32035nKhs32035nps ... Show all

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