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Kelly Jaguar series KLS-RM Sinusoidal BLDC Motor Controller User Manual
Passenger Vehicle &Racing Sinusoidal BLDC Motor Controllers
KLS7225RM
KLS7260RM
KLS8425RM
KLS8480RM
KLS1270RMO
KLS1460RMO
KLS1680RMO
Kelly KLS-RM series
User Manual
Devices Supported:
KLS7230RM
KLS7260RM
KLS8428RM
KLS84100RM
KLS1285RMO
KLS12100RMO
KLS1475RMO
KLS16100RMO
KLS16130RMO
KLS7235RM
KLS8430RM
KLS84120RM
KLS84150RMO
KLS12130RMO
KLS1490RMO
KLS14110RMO
KLS7240RM
KLS7245RM
KLS8445RM
KLS8460RM
KLS84180RMO
KLS12160RMO
KLS14140RMO
V2.1.0
Rev. 2.1.0
Sep. 2024
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Summary of Contents for Kelly Jaguar KLS-RM Series
- Page 1 Kelly Jaguar series KLS-RM Sinusoidal BLDC Motor Controller User Manual V2.1.0 Kelly KLS-RM series Passenger Vehicle &Racing Sinusoidal BLDC Motor Controllers User Manual Devices Supported: KLS7225RM KLS7230RM KLS7235RM KLS7240RM KLS7245RM KLS7260RM KLS7260RM KLS8425RM KLS8428RM KLS8430RM KLS8445RM KLS8460RM KLS8480RM KLS84100RM KLS84120RM...
- Page 2 Kelly Jaguar series KLS-RM 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 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 Jaguar series KLS-RM 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-RM 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 KLS1270RMO 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 Jaguar series KLS-RM Sinusoidal BLDC Motor Controller User Manual V2.1.0 Kelly KLS-RM------Racing Motor controllers Model Nominal Voltage Max Operating Boost Current Continuous Current Continuous Current Voltage (20 seconds) (liquid cooling) KLS7225RM 48-72V 36-86V 250A 100A KLS7230RM 48-72V 36-86V 300A...
- Page 8 Kelly Jaguar series KLS-RM 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 Jaguar series KLS-RM Sinusoidal BLDC Motor Controller User Manual V2.1.0 Figure 2: KLS7235RM KLS7240RM KLS8430RM KLS8445RM mounting holes’ dimensions (dimensions in millimeters) B+,B-,U,V,W:M6 Bolts...
- Page 10 Kelly Jaguar series KLS-RM Sinusoidal BLDC Motor Controller User Manual V2.1.0 Figure 3: KLS7245RM mounting holes’ dimensions (dimensions in millimeters) B+,B-,U,V,W:M6 Bolts...
- Page 11 Kelly Jaguar series KLS-RM Sinusoidal BLDC Motor Controller User Manual V2.1.0 Figure 1: KLS8425RM mounting holes’ dimensions (dimensions in millimeters) B+,B-,U,V,W:M5 Bolts Figure 3: KLS8428RM mounting holes’ dimensions (dimensions in millimeters) B+,B-,U,V,W:M6 Bolts...
- Page 12 Kelly Jaguar series KLS-RM Sinusoidal BLDC Motor Controller User Manual V2.1.0 Figure 4: KLS8460RM mounting holes’ dimensions (dimensions in millimeters) B+,B-,U,V,W:M6 Bolts...
- Page 13 Kelly Jaguar series KLS-RM Sinusoidal BLDC Motor Controller User Manual V2.1.0 Figure 4: KLS7250RM KLS7260RM mounting holes’ dimensions (dimensions in millimeters) B+,B-,U,V,W:M8 Bolts...
- Page 14 Kelly Jaguar series KLS-RM Sinusoidal BLDC Motor Controller User Manual V2.1.0 Figure 5: KLS8480RM KLS84100RM KLS84120RM KLS1270RMO KLS1280RMO KLS12100RMO KLS1460RMO mounting holes’ dimensions (dimensions in millimeters) B+,B-,U,V,W:M8 Bolts...
- Page 15 Kelly Jaguar series KLS-RM Sinusoidal BLDC Motor Controller User Manual V2.1.0 Figure 5: KLS8480RM KLS84100RM KLS84120RM KLS1270RMO KLS1280RMO KLS12100RMO KLS1460RMO With Aluminum Liquid Cooling Heatsink at the bottom mounting holes’ dimensions (dimensions in millimeters) B+,B-,U,V,W:M8 Bolts...
- Page 16 Kelly Jaguar series KLS-RM Sinusoidal BLDC Motor Controller User Manual V2.1.0 Figure 6: KLS-RMO model with Sealed Aluminium Housing mounting holes’ dimensions (dimensions in millimeters) B+,B-,U,V,W:M8 Bolts...
- Page 17 Kelly Jaguar series KLS-RM Sinusoidal BLDC Motor Controller User Manual V2.1.0 Figure 7: Sealed Aluminium Housing with Liquid Cooling Heatsink at the bottom Mounting holes’ dimensions (dimensions in millimeters) B+,B-,U,V,W:M8 Bolts...
- Page 18 Kelly Jaguar series KLS-RM Sinusoidal BLDC Motor Controller User Manual V2.1.0 3.2 Connections 3.2.1 Pin definition of KLS-RM 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 19 Kelly Jaguar series KLS-RM 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 20 Kelly Jaguar series KLS-RM Sinusoidal BLDC Motor Controller User Manual V2.1.0 3.2.2 KLS-RM Controller Standard Wiring Figure 11: KLS-RM 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 21 Kelly Jaguar series KLS-RM 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 22 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 23 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 24 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 25 Kelly Jaguar series KLS-RM 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 26 Kelly Jaguar series KLS-RM 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 27 Kelly Jaguar series KLS-RM 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 28 Kelly Jaguar series KLS-RM 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 29 Kelly Jaguar series KLS-RM 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 30 Kelly Jaguar series KLS-RM 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 31 Kelly Jaguar series KLS-RM 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 32 Kelly Jaguar series KLS-RM 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 33 Kelly Jaguar series KLS-RM 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 34 Kelly Jaguar series KLS-RM 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 35 Kelly Jaguar series KLS-RM 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 ¤¤¤...
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