Kelly KHS Series User Manual

High voltage opto-isolated sinusoidal bldc motor controllers

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Kelly KHS series Opto-Isolated Sinusoidal BLDC Motor Controller User Manual

High Voltage Opto-Isolated Sinusoidal BLDC Motor Controllers

KHS32020I

KHS36020I

KHS32020IPS

Kelly KHS series

User Manual

Devices Supported:

KHS32030N

KHS36025N

KHS32030NPS

KHS32025NPS

KHS32035N

KHS36030N

KHS32035NPS

KHS32030NPS

KHS32040N

KHS36035N

KHS32040NPS

KHS32035NPS

Rev. 2.1.0

Sep. 2024

V2.1.0

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Summary of Contents for Kelly KHS Series

Page 1 Kelly KHS series Opto-Isolated Sinusoidal BLDC Motor Controller User Manual V2.1.0 Kelly KHS series High Voltage Opto-Isolated Sinusoidal BLDC Motor Controllers User Manual Devices Supported: KHS32020I KHS32030N KHS32035N KHS32040N KHS36020I KHS36025N KHS36030N KHS36035N KHS32020IPS KHS32030NPS KHS32035NPS KHS32040NPS KHS32020IPS KHS32025NPS KHS32030NPS KHS32035NPS Rev.
Page 2 Kelly KHS series Opto-Isolated Sinusoidal BLDC Motor Controller User Manual V2.1.0 Contents Chapter 1 Introduction ................2 1.1 Overview........................ 2 Chapter 2 Features and Specifications ............ 2.1 General functions ....................3 2.2 Features ........................ 4 2.3 Specifications ......................5 2.4 Name Regulation ....................6 Chapter 3 Wiring and Installation .............
Page 3 KHS is a sinusoidal motor controller specifically equipped with optical isolation to meet high voltage(Up to 360V) requirements. This manual introduces the features, installation, and maintenance of the Kelly sinusoidal brushless DC (BLDC) motor controller. Please read the manual carefully before using the controller.
Page 4 8. The controller can be programmed and configured using user program or an Android app. For the PC side, please connect the controller and PC using a Kelly USB cable or a USB-RS232 set to use the user program. For the Android side, please connect the controller to a Bluetooth adapter which purchased from out site to use the configuration app on Android devices.
Page 5 Kelly KHS series Opto-Isolated Sinusoidal BLDC Motor Controller User Manual V2.1.0 22. CAN Bus (Optional), broadcast type, with a customizable baud rate(default at 250Khz) . CAN bus is not included by default in KHS controllers. 23. Bidirectional anti-slip function (Optional), Prevent the stationary vehicle moving in the opposite direction.
Page 6 Kelly KHS series Opto-Isolated Sinusoidal BLDC Motor Controller User Manual V2.1.0 21. Supports motors with any number of poles. 22. Standard electrical speed up to 70,000 eRPM (electrical speed = mechanical speed * number of pole pairs; number of pole pairs = number of poles / 2).
Page 7 Kelly KHS series Opto-Isolated Sinusoidal BLDC Motor Controller User Manual V2.1.0 2.4 Name Regulation The name regulation of Kelly BLDC motor controllers KHS32020I/KHS32030NPS For example: : Kelly optical-isolated BLDC motor controller based on sinusoidal waveform which is suitable for operation under high voltage. KHS controllers can do regen brake function by default.
Page 8 Kelly KHS series Opto-Isolated Sinusoidal BLDC Motor Controller User Manual V2.1.0 Chapter 3 Wiring and Installation 3.1 Mounting the Controller The controller can be placed anywhere but should be kept as clean and dry as possible. If necessary, covering with a cover to prevent water and contaminants from entering.
Page 9 Kelly KHS series Opto-Isolated Sinusoidal BLDC Motor Controller User Manual V2.1.0 Figure 1: KHS-I series mounting holes’ dimensions (dimensions in millimeters) +/B+/B-/U/V/W:M8...
Page 10 Kelly KHS series Opto-Isolated Sinusoidal BLDC Motor Controller User Manual V2.1.0 Figure 2: KHS-N series mounting holes’ dimensions (dimensions in millimeters) +/B+/B-/U/V/W:M8...
Page 11 Kelly KHS series Opto-Isolated Sinusoidal BLDC Motor Controller User Manual V2.1.0 3.2 Connections 3.2.1 Pin definition of KHS Controller waterproof connector Figure 10: DJ7091Y-2.3-11 Pin Definition 1. REV_SW(14): Reverse switch input. ※Orange 2. GND(6): Signal return or power supply return. ※Black 3.
Page 12 Kelly KHS series Opto-Isolated Sinusoidal BLDC Motor Controller User Manual V2.1.0 3. GND(20): Signal return. ※Black 4. Meter(8): Copied signal of hall-A sensor. ※Dark Gray 5. 5V(4): 5V Supply, <40mA. ※Purple Brake_AN(2): Brake variable regen or Boost function. ※Brown 12V(11): 12V Supply. ※Red DJ7061Y-2.3-21 Pin Definition...
Page 13 Kelly KHS series Opto-Isolated Sinusoidal BLDC Motor Controller User Manual V2.1.0 3.2.2 KHS Controller Standard Wiring Figure 11: KHS controller standard wiring (Battery is also used as controller’s power supply) Caution! Make sure the controller wiring is correct and has been double checked, especially the B+ and the B- of the controller before power on.
Page 14 Kelly KHS series Opto-Isolated Sinusoidal BLDC Motor Controller User Manual V2.1.0 3.2.3 Communication Port A 4pin connector is provided to communicate with host for calibration and configuration. Figure 12: SM-4P connector 3.3 Installation Check List 1. Conduct a visual inspection to ensure that components such as mounting holes, wiring, and sealing rings are intact.
Page 15 3. Use the RS232-USB cable and SM-4P adapter provided by Kelly to connect to a host computer. During the opeartion, the PWR of the controller needs to be provided with >+18V (for a 24V controller, provide >+8V).
Page 16 You have three way to connect the controller to host computers or Android devices: 1. Using Kelly USB cable, connect SM-4P(Female) from controller to the USB port on computer. You may download Kelly USB Cable driver or at our website.
Page 17 11). Please make sure there is no load on the motor shaft before starting the programming. 2. Connect the controller to PC by using a Kelly USB cable or an USB to RS232 set. For Android devices, please use the Bluetooth adapter to connect the controller.
Page 18 Kelly KHS series Opto-Isolated Sinusoidal BLDC Motor Controller User Manual V2.1.0 6. Turn on the power supply after the power supply is off for a few seconds. The motor shaft will try to run on random directions. This is a normal operating phenomenon.
Page 19 Kelly KHS series Opto-Isolated Sinusoidal BLDC Motor Controller User Manual V2.1.0 4.3 Program parameters and value On program’s initial interface, these items are listed: Default Possible Source of Number Parameter Description Value Value Value* Model Name Controller Model. Default User Name User code, to identify controller variants.
Page 20 Kelly KHS series Opto-Isolated Sinusoidal BLDC Motor Controller User Manual V2.1.0 Throttle Type, User TPS Type 1 / 2 1: 0-5K,resistance pedal; Configuration 2: 0,5V,Hall active pedal; Throttle Dead Zone Lower Limit, User TPS Dead Low 0-60% 20%*5V=1V. Configuration Throttle Dead Zone Higher Limit,...
Page 21 Kelly KHS series Opto-Isolated Sinusoidal BLDC Motor Controller User Manual V2.1.0 User PWM frequency 10 / 16 / 20 PWM modulation frequency (Khz) Configuration Kp of Q-ring, the proportional gain in Q-ring current loop, is mainly effective at speeds below 400 RPM. Increasing this...
Page 22 Kelly KHS series Opto-Isolated Sinusoidal BLDC Motor Controller User Manual V2.1.0 Brake pedal regen’s regen strength, User BRK_AD Brk 0-50% 0= no regen. Configuration When the anti-theft function is activated, the percentage of the User Anti-theft 0-30% motor's locking current to the maximum current.
Page 23 Kelly KHS series Opto-Isolated Sinusoidal BLDC Motor Controller User Manual V2.1.0 Limit of Kp and Ki in torque mode, need to be adjusted at User Speed Err Limit 50-4000 1000 same time when adjusting Configuration Kp and Ki in torque mode.
Page 24 Kelly KHS series Opto-Isolated Sinusoidal BLDC Motor Controller User Manual V2.1.0 An error will be reported when the amplitude of the sine/cosine sensor signal exceeds this value. User Line Hall High 1-1023 this value / 1024 * 5 = actual voltage value (Volts).
Page 25 Kelly KHS series Opto-Isolated Sinusoidal BLDC Motor Controller User Manual V2.1.0 Neutral High-pedal function checked/ Checked: the first time throttle being pressed after switching User NTL H-Pedal unchecked unchecked gears, the controller will report a high pedal error to prevent Configuration accidental starting, need to step on the pedal again to start.
Page 26 Kelly KHS series Opto-Isolated Sinusoidal BLDC Motor Controller User Manual V2.1.0 Anti-Slip function checked/ Checked: enable anti-slip function, User Anti-Slip unchecked unchecked The motor will resist rotation to prevent the vehicle from Configuration moving due to external forces. Change Direction function Checked: Swap the forward and backward directions.
Page 27 Kelly KHS series Opto-Isolated Sinusoidal BLDC Motor Controller User Manual V2.1.0 Table 1: Error Codes Buzzer Error Codes Error code Explanation Solution 1. Check Phase line or Hall line. Auto-Identification 2. Check Hall power line(+5V and GND). 1, 1 ¤...
Page 28 Kelly KHS series Opto-Isolated Sinusoidal BLDC Motor Controller User Manual V2.1.0 fix the issue, check if the throttle is functioning properly. Reserved 3, 1 ¤¤¤ ¤ Current is too high or current fluctuations are too large. Internal reset Reduce the phase current and check if the 5V and 12V 3, 2 ¤¤¤...

This manual is also suitable for:

Khs32020i Khs32030n Khs32035n Khs32040n Khs36020i Khs36025n ... Show all