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Kelly KLS-N Series User Manual

High-current sinusoidal bldc motor controllers
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Kelly High-current KLS-N series Sinusoidal BLDC Motor Controller User Manual
Kelly High-current KLS-N series
High-current Sinusoidal BLDC Motor Controllers
KLS4860NT
KLS4875N
KLS7275NT
KLS7275N
KLS8475N
KLS84100N
User Manual
Devices Supported:
KLS48100N
KLSAA72100N
KLS84120N
KLS48120N
KLS72120N
KLS72150N
V2.1.0
Rev. 2.1.0
Sep. 2024

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Summary of Contents for Kelly KLS-N Series

  • Page 1 Kelly High-current KLS-N series Sinusoidal BLDC Motor Controller User Manual V2.1.0 Kelly High-current KLS-N series High-current Sinusoidal BLDC Motor Controllers User Manual Devices Supported: KLS4860NT KLS4875N KLS48100N KLS48120N KLS7275NT KLS7275N KLSAA72100N KLS72120N KLS72150N KLS8475N KLS84100N KLS84120N Rev. 2.1.0 Sep. 2024...
  • Page 2 Kelly High-current KLS-N series 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 ....................5 Chapter 3 Wiring and Installation .............
  • Page 3 KLS-N HC is a variant of the standard KLS-N model, offering significant performance improvements in a larger size, while still maintaining the same IP66 protection. 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 High-current KLS-N series 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 KLS-N controllers. 23. Bidirectional anti-slip function (Optional), Prevent the stationary vehicle moving in the opposite direction.
  • Page 6 The name regulation of Kelly BLDC motor controllers KLS7275NT For example: : 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 Kelly High-current KLS-N series Sinusoidal BLDC Motor Controller User Manual V2.1.0 Kelly KLS-N - Sinusoidal Brushless Permanent Magnet Motor Controller Model Nominal Max Operating Peak Current Continuous Voltage Voltage 2 Minutes Current KLS4860NT 36-48V 27-60V 400A 160A-240A KLS4875N 36-48V 27-60V...
  • Page 8 Kelly High-current KLS-N series Sinusoidal BLDC Motor Controller User Manual V2.1.0 Figure 7: KLS4860NT KLS7275NT mounting holes’ dimensions (dimensions in millimeters) +/B+/B-/U/V/W:M8...
  • Page 9 Kelly High-current KLS-N series Sinusoidal BLDC Motor Controller User Manual V2.1.0 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 KLS-N series Sinusoidal BLDC Motor Controller User Manual V2.1.0 Figure 11: With Aluminum Liquid Cooling Heatsink at the bottom mounting holes’ dimensions (dimensions in millimeters) +/B+/B-/U/V/W:M8...
  • Page 11 Kelly High-current KLS-N series Sinusoidal BLDC Motor Controller User Manual V2.1.0 3.2 Connections 3.2.1 Pin definition of KLS-N 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 High-current KLS-N series 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 High-current KLS-N series Sinusoidal BLDC Motor Controller User Manual V2.1.0 3.2.2 KLS-N Controller Standard Wiring Figure 11: KLS-N 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 High-current KLS-N series 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 High-current KLS-N series 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 High-current KLS-N series 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 High-current KLS-N series 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 High-current KLS-N series 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 High-current KLS-N series 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 High-current KLS-N series 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 High-current KLS-N series 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 High-current KLS-N series 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 High-current KLS-N series 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 High-current KLS-N series 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 High-current KLS-N series 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:

Kls4860ntKls4875nKls48100nKls48120nKls7275ntKls7275n ... Show all