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Kelly KLS-RM series
Sinusoidal Brushless PM Motor Controllers with higher boost current.
KLS7225RM
KLS7230RM
KLS7235RM
KLS7240RM
KLS7245RM
KLS7250RM
KLS7260RM
User's Manual
Devices Supported:
KLS8425RM
KLS84150RMO
KLS8428RM
KLS84180RMO
KLS8430RM
KLS1170RMO
KLS8445RM
KLS1185RMO
KLS8460RM
KLS11100RMO
KLS8480RM
KLS11130RMO KLS16100RMO
KLS84100RM KLS11160RMO KLS16130RMO
KLS84120RM
KLS1460RMO
KLS1490RMO
KLS14110RMO
KLS14140RMO
KLS1680RMO
Rev.1.24
Feb. 2024
1
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Table of Contents
Related Manuals for Kelly KLS1490RMO
Summary of Contents for Kelly KLS1490RMO
- Page 1 Kelly KLS-RM series Sinusoidal Brushless PM Motor Controllers with higher boost current. User’s Manual Devices Supported: KLS7225RM KLS8425RM KLS84150RMO KLS1460RMO KLS7230RM KLS8428RM KLS84180RMO KLS1490RMO KLS7235RM KLS8430RM KLS1170RMO KLS14110RMO KLS7240RM KLS8445RM KLS1185RMO KLS14140RMO KLS7245RM KLS8460RM KLS11100RMO KLS1680RMO KLS7250RM KLS8480RM KLS11130RMO KLS16100RMO...
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Page 2: Table Of Contents
Contents Chapter 1 Introduction ....................3 1.1 Overview ......................3 Chapter 2 Features and Specifications ............... 4 2.1 General functions ....................4 2.2 Features ......................5 2.3 Specifications ....................6 2.4 Name Regulation ....................6 Chapter 3 Wiring and Installation ................7 3.1 Mounting the Controller ................... -
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
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
included in KLS-N controller by default.CAN bus is only an optional function for KLS-N. (22) Bidirectional anti-slip function(Optional) , Prevent the stationary vehicle moving in the opposite direction. After the function enabled, when the controller detects that the motor turns from standstill to the opposite direction, it will drive the motor to provide some braking force, making the vehicle stops or slows down. -
Page 6: Specifications
The name regulation of Kelly BLDC motor controllers KLS7225RM 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-RMO------Opto-isolated Racing Motor controllers Model Nominal Boost Continuous Continuous Current Voltage Operating Current Current (liquid cooling) Voltage 30 seconds KLS84150RMO 48-84V 36-100V 1500A 400A 550A KLS84180RMO 48-84V 36-100V 1800A 460A 630A KLS1170RMO 48-110V 36-132V 700A 230A 280A KLS1185RMO 48-110V... - Page 8 The case outline and mounting holes’ dimensions are shown below. Figure 1: KLS7225RM KLS7230RM KLS8428RM mounting holes’ dimensions (dimensions in millimeters)
- Page 9 Figure 1: KLS8425RM mounting holes’ dimensions (dimensions in millimeters)
- Page 10 Figure 2: KLS7235RM KLS7240RM KLS8430RM KLS8445RM mounting holes’ dimensions (dimensions in millimeters)
- Page 11 Figure 3: KLS7245RM mounting holes’ dimensions (dimensions in millimeters)
- Page 12 Figure 3: KLS8428RM mounting holes’ dimensions (dimensions in millimeters)
- Page 13 Figure 4: KLS8460RM mounting holes’ dimensions (dimensions in millimeters)
- Page 14 Figure 4: KLS7250RM KLS7260RM mounting holes’ dimensions (dimensions in millimeters)
- Page 15 Figure 5: KLS8480RM KLS84100RM KLS84120RM KLS1170RMO KLS1180RMO KLS11100RMO KLS1460RMO mounting holes’ dimensions (dimensions in millimeters)
- Page 16 Figure 5: KLS8480RM KLS84100RM KLS84120RM KLS1170RMO KLS1180RMO KLS11100RMO KLS1460RMO With Aluminum Liquid Cooling Heatsink at the bottom mounting holes’ dimensions (dimensions in millimeters)
- Page 17 Figure 6: KLS-RMO model with Sealed Aluminium Housing mounting holes’ dimensions (dimensions in millimeters)
- Page 18 Figure 7: Sealed Aluminium Housing with Liquid Cooling Heatsink at the bottom Mounting holes’ dimensions （dimensions in millimeters）...
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Page 19: Connections
3.2 Connections 3.2.1 Pin definition of KLS-N Controller waterproof connector Figure 10:... - Page 20 Figure 11:Compact connectors...
- Page 21 Figure 12: Mini waterproof connectors 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. 4, CAN bus is not included in KLS-N controller by default. When boost is disabled in user program，...
- Page 22 DJ7091Y-2.3-11 Pin Definition (14) REV_SW: Reverse switch input. Orange (6) RTN: Signal return or power supply return. Black (12) FWD: Forward switch or can be enabled as High speed switch function. White (11) 12V:12V Source Red . Yellowish (25) 12V brake switch (22) ECO: Low speed switch function.
- Page 23 3.2.2 Standard Wiring of KLS-N Controller 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 24 Figure 12: Wiring of brake switch(12V): 12V is provided by external source. 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. 3.2.4 Communication Port A 4pin connector to RS232 port is provided to communicate with host computer for calibration and configuration.
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Page 25: Installation Check List
Figure 16：SM-4P connector for communication interface on KLS-N controller 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 26: Chapter 4 Programmable Parameters
acceleration and good power. 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 27 (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 28 type at 2. As the same goes,it is valid to adjust the high threshold voltage above 4.5V or below 4.5V. Usually the hall output voltage is 4.2V Max.If you adjust it to lower value which is near 4.2V,it may trigger the error code in normal way. (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.
- Page 29 Range: 20~100 By default, it is set at 100%.Both F-N-R control and three speed function used the same pin12.Needless to say, we can not use both functions at the same time. Three Gears switch is supposed to enable F-N-R control. When this item is disabled, we can use three speed function, vice versa.
- Page 30 way. The motor speed will increase when the throttle is from 0V to 5V. If you enable joystick for this controller in user program, you will start the motor from 2.5V position.2.6V to 5V is forward.2.4V to 0V is backward. 2.4V to 2.6V is the throttle dead zone.
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Page 31: Step 2
The boost function is still based on limiting of the motor current and battery current settings in user program. If disabled, the controller can provide brake sensor regen mode on the same pin as pin2.In simple, boost and brake analog regen used the same pin as pin2. Suggestion: Set according to the practical situation, factory default is Disable. -
Page 32: Step 3
Suggestion: Set according to the real motor poles on the nameplate of the motor, factory default is at 8. (3)Speed Sensor Type: Speed Sensor Type, 2:Hal, 3:Resolver, 4:Line Hall. Range: 2~4 Different sensors type. By defualt, it is set at 2 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. - Page 33 (5)Brake Time: Brake Time, the time of Brake Torque from 0 to max, accuracy 0.1s. Range: 1~250 Factory set is 15 (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.
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Page 34: How To Use Identification Angle Operation Function
(13)Torque Speed Kp:3000 Torque Speed Ki:80 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. Note: Thermistor is optional. - Page 35 2,Please connect the controller to user program by using an USB to RS232 cable and SM-4A DB9(RS232) Converter.
- Page 36 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. We don’t have to use SM-4A to DB9(RS232) converter any more when you use Bluetooth converter for programming the controller.
- Page 37 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 38 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. That is to say, the controller identification angle operation is successful. You can use the KLS-N/M controller to drive the motor now.
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Page 39: 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 40 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 41 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. 4. If this error code occurs,the relay function on plin9 will be deactivated.
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Page 42: Contact Us
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...