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Related Manuals for Kelly High-current KLS-N Series
Summary of Contents for Kelly High-current KLS-N Series
- Page 1 Kelly High-current series KLS-N V1.25 Kelly High-current series KLS-N Sinusoidal Brushless Permanent Magnet Motor Controllers User’s Manual Devices Supported: KLS4860NT KLS7275NT KLS8475N KLS4875N KLS7275N KLS84100N KLS48100N KLS72100N KLS84120N KLS48120N KLS72120N KLS72150N Rev.1.29 Jul. 2024...
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Page 2: Table Of Contents
Kelly High-current series KLS-N V1.25 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 ................ -
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 High-current series KLS-N V1.25 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 High-current series KLS-N V1.25 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 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 High-current series KLS-N V1.25 KLS72150N 48-72V 36-86V 800A 320A-480A KLS8475N 48-84V 36-100V 500A 200A-300A KLS84100N 48-84V 36-100V 600A 240A-360A KLS84120N 48-84V 36-100V 700A 280A-420A 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 High-current series KLS-N V1.25 Figure 7: KLS4860NT KLS7275NT mounting holes’ dimensions (dimensions in millimeters) +/B+/B-/U/V/W:M...
- Page 9 Kelly High-current series KLS-N V1.25 Figure 9: KLS4875N KLS48100N KLS48120N KLS7275N KLS72100N KLS72120N KLS72150N KLS8475N KLS84100N KLS84120N KLS84150N mounting holes’ dimensions (dimensions in millimeters) +/B+/B-/U/V/W:M8...
- Page 10 Kelly High-current series KLS-N V1.25 Figure 11: With Aluminum Liquid Cooling Heatsink at the bottom mounting holes’ dimensions (dimensions in millimeters) +/B+/B-/U/V/W:M8...
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Page 11: Connections
Kelly High-current series KLS-N V1.25 3.2 Connections 3.2.1 Pin definition of KLS-N Controller waterproof connector Figure 10: 1，The switch signal is valid to 12V 2，12V only can be used for LED or switch signals , with a total current not exceeding 20mA 3，Boost and brake analog regen use the same port on pin2. - Page 12 Kelly High-current series KLS-N V1.25 (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. Dark Gray (4) 5V: 5V supply output, <40mA.
- Page 13 Kelly High-current series KLS-N V1.25 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 14 Kelly High-current series KLS-N V1.25 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 15: Installation Check List
Kelly High-current series KLS-N V1.25 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 16: Chapter 4 Programmable Parameters
Kelly High-current series KLS-N V1.25 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 17 (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 18 Kelly High-current series KLS-N V1.25 (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 19 Kelly High-current series KLS-N V1.25 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 20 Kelly High-current series KLS-N V1.25 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. Please check the wiring diagram in the manual for F-N-R control.
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Page 21: Step 2
Kelly High-current series KLS-N V1.25 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. If there is no foot switch signal, the controller will ignore the throttle signal. -
Page 22: Step 3
Kelly High-current series KLS-N V1.25 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 23 Kelly High-current series KLS-N V1.25 (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 24: How To Use Identification Angle Operation Function
Kelly High-current series KLS-N V1.25 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 25 Kelly High-current series KLS-N V1.25 2,Please connect the controller to user program by using an USB to RS232 cable and SM-4A DB9(RS232) Converter.
- Page 26 Kelly High-current series KLS-N V1.25 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 27 Kelly High-current series KLS-N V1.25 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.
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Page 28: Chapter 5 Maintenance
Kelly High-current series KLS-N V1.25 You can use the KLS-N/M controller to drive the motor now. 11,As long as it is not reset error code, the value in identification angle will not go back to 85.The value is always at 170.That is to say, the controller is still in the processing of identification operation. -
Page 29: Cleaning
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 30 1. Measure that B+ & PWR are correct when measured to B- or RTN. 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...
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Page 31: Contact Us
Kelly High-current series KLS-N V1.25 warranty repair. 4. If this error code occurs,the relay function on plin9 will be deactivated. Over temperature ¤¤ ¤¤¤ The controller temperature has exceeded 100℃. The controller will be stopped but will restart when temperature falls below 80℃. - Page 32 Kelly High-current series KLS-N V1.25 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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