This manual introduces the Kelly Small 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.
Kelly KLS-S Cheetah series Sinusoidal Permanent Motor Controller User’s Manual V1.26 Chapter 2 Features and Specifications 2.1 General functions (1) Extended fault detection and protection. The LED flashing pattern indicates the fault sources. Customers can read the error message in PC software or Android APP also.
Cheetah series Kelly KLS-S Sinusoidal Permanent Motor Controller User’s Manual V1.26 (21) 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. (22) Can support three speed function on the latest version.
2.4 Name Regulation The name regulation of Kelly BLDC motor controllers KLS7230S KLS: Kelly BLDC motor controller based on sinusoidal waveform which is supposed to work with BLDC motor with three hall sensors. 72: 72V batteries S: Mini case for the controller...
Cheetah series Kelly KLS-S Sinusoidal Permanent Motor Controller User’s Manual V1.26 KLS8412Z 48-84 40-100 KLS8418Z 48-84 40-100 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-S Cheetah series Sinusoidal Permanent Motor Controller User’s Manual V1.26 mounting holes’ dimensions Figure 2:KLS-18S (dimensions in millimeters)
Page 9
Cheetah series Kelly KLS-S Sinusoidal Permanent Motor Controller User’s Manual V1.26 mounting holes’ dimensions Figure 3: KLS-30S (dimensions in millimeters)
Page 10
Kelly KLS-S Cheetah series Sinusoidal Permanent Motor Controller User’s Manual V1.26 Figure 4: KLS-4812Z KLS7212Z KLS8412Z mounting holes’ dimensions (dimensions in millimeters)
Page 11
Cheetah series Kelly KLS-S Sinusoidal Permanent Motor Controller User’s Manual V1.26 Figure 5: KLS-4818Z KLS7218Z KLS8418Z mounting holes’ dimensions (dimensions in millimeters)
Kelly KLS-S Cheetah series Sinusoidal Permanent Motor Controller User’s Manual V1.26 3.2 Connections 3.2.1 Pin definition of KLS-S Controller Waterproof connectors Figure 4:...
Page 13
Cheetah series Kelly KLS-S Sinusoidal Permanent Motor Controller User’s Manual V1.26 Figure 5:Compact connectors...
Page 14
Kelly KLS-S Cheetah series Sinusoidal Permanent Motor Controller User’s Manual V1.26 Figure 6: Mini waterproof connectors 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 15
Cheetah series Kelly KLS-S Sinusoidal Permanent Motor Controller User’s Manual V1.26 DJ7091Y-2.3-11 Pin Definition (14) REV_SW: Reverse switch input,Orange. (6) GND: Signal return or power supply return,Black. (12) FWD: Forward switch or High speed switch,White. (11) 12V:12V Source,Red. (22) ECO: Low speed switch input,Blue.
Page 16
Kelly KLS-S Cheetah series Sinusoidal Permanent Motor Controller User’s Manual V1.26 • The preferred connection of the system contactor or circuit breaker is in series with the B+ line. • All contactors or circuit breakers in the B+ line must have precharge resistors across their contacts.
Page 17
Cheetah series Kelly KLS-S Sinusoidal Permanent Motor Controller User’s Manual V1.26 Figure 6: KLS-S controller standard wiring(Three speed function control) (Battery voltage can be used for controller supply) 3.2.2.2 Optional wiring of KLS-S controller The 12V input signal of the pin supplies the second braking function of the controller.
Page 18
Kelly KLS-S Cheetah series Sinusoidal Permanent Motor Controller User’s Manual V1.26 Figure 8: Wiring of brake switch(12V): 12V is provided by KLS-S controller on pin11 Figure 9: Wiring diagram for motor temperature sensor 3.2.3 Communication Port A 4pin connector to RS232 port is provided to communicate with host computer for calibration and configuration.
Cheetah series Kelly KLS-S Sinusoidal Permanent Motor Controller User’s Manual V1.26 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. Caution: • Put the vehicle up on blocks to get the drive wheels off the ground before beginning these tests.
Kelly KLS-S Cheetah series Sinusoidal Permanent Motor Controller User’s Manual V1.26 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 21
(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 22
Kelly KLS-S Cheetah series Sinusoidal Permanent Motor Controller User’s Manual V1.26 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. 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 23
Cheetah series Kelly KLS-S Sinusoidal Permanent Motor Controller User’s Manual V1.26 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 24
Kelly KLS-S Cheetah series Sinusoidal Permanent Motor Controller User’s Manual V1.26 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.
Cheetah series Kelly KLS-S Sinusoidal Permanent Motor Controller User’s Manual V1.26 (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. If there is no foot switch signal, the controller will ignore the throttle signal.
Kelly KLS-S Cheetah series Sinusoidal Permanent Motor Controller User’s Manual V1.26 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. (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 27
Cheetah series Kelly KLS-S Sinusoidal Permanent Motor Controller User’s Manual V1.26 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. You have to turn on the brake switch after the throttle is released for the regen to occur.
Kelly KLS-S Cheetah series Sinusoidal Permanent Motor Controller User’s Manual V1.26 Note: Thermistor is optional. Default to KTY84-130/150 or KTY83-122 When controller temp item shows 246 in monitor screen of user program, it is normal. This item is only useful for internal calculation for MCU.246 is about 11 degrees in environment.
Page 29
Cheetah series Kelly KLS-S Sinusoidal Permanent Motor Controller User’s Manual V1.26 DB9(RS232) Converter. 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...
Page 30
Kelly KLS-S Cheetah series Sinusoidal Permanent Motor Controller User’s Manual V1.26 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.Then you may try to click Read button in user program or App.You will see the first picture of user program.
Page 31
Cheetah series Kelly KLS-S Sinusoidal Permanent Motor Controller User’s Manual V1.26 blink 3-2 code. The Green LED will be off. And you will see reset error message in the monitor screen of user program of KLS-S controller. 9,Please turn off the power supply again. Please wait about a few seconds to turn on the power supply one more time.
Kelly KLS-S Cheetah series Sinusoidal Permanent Motor Controller User’s Manual V1.26 Note:If the main contactor is not closed completely, defective throttle or wiring, low battery capacity, short circuit wiring etc happen, it will affect the identification angle operation. The controller may report Identify error so as to trigger Hall Err which means the identification angle operation is failure.
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.
Kelly KLS-S Cheetah series Sinusoidal Permanent Motor Controller User’s Manual V1.26 Table 1: LED CODES Green LED Codes LED Code Explanation Solution No power or Green Off 1. Check if all wires are correct. switched off 2. Check fuse and power supply.
Cheetah series Kelly KLS-S Sinusoidal Permanent Motor Controller User’s Manual V1.26 potentiometers or incorrect wiring. 3. Controller is damaged. Contact Kelly about a warranty repair. Over temperature ¤¤ ¤¤¤ The controller temperature has exceeded 100℃. The controller will be stopped but will restart when temperature falls below 80℃.
Page 36
Kelly KLS-S Cheetah series Sinusoidal Permanent Motor Controller User’s Manual V1.26 www.kellycontroller.com/support.php E-mail: Sales@Kelly-Controls.com Phone: (01) 224 637 5092...