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Kelly KLS-S Cheetah series Sinusoidal Permanent Motor Controller User

’s Manual 

   

      V1.13 

                                                                                                                                         

 

2

 

 

Chapter 

1    Introduction

 

1.1 Overview 

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‟s  programmable  motor

 

controllers  provide  efficient,  smooth  and  quiet  controls  for 

electric  motorcycles,  golf  carts  and  go-carts,  as  well  as  industrial  motor  control.  It  is  mainly 
supposed  to  solve  noise  problems  of  BLDC  motor  driving  application.  The  KLS-S  motor 
controller  must  be  based  on  hall  sensors  type.  KLS-S  controller  can  not  support  sensorless 
brushess motor for now. Compared to the traditional trapezoidal waveform control technology, 
this technique based on sinusoidal wave driving technology can reduce the operation noise and 
1/3  switching  loss,  which  well  meets  the  noise  reduction  and  efficiency  requirements  in  the 
application  of  DC  brushless  motor. 

It uses high power MOSFET‟s and, SVPWM  and FOC  to 

achieve  efficiencies  of  up  to  99%  in  most  cases.  A  powerful  microprocessor  brings  in 
comprehensive and precise control to the controllers. It also allows users to adjust parameters, 
conduct  tests,

 

and  obtain  diagnostic  information  quickly  and  easily.  People  can  program  the 

KLS  controller  on  PC  software  and  Android  App.  There  is  one  more  choice  for  customers  to 
program KLS controller now. The APP software is based on Tablet with Android OS. Customers 
may  add  a  Z-TEK  USB  to  RS232  cable  for  programming  KLS  controller  if  they  want  to  use 
Android Tablet. 

Both  PC  software  and  Android  APP  can  provide  one  screen  to  monitor  the  controller 

parameters. Sometimes people can use a small Android Tablet as display device. 

 

 

 

 

Anyway please try to do identification angle operation before running the motor. 

And please don't try to connect the controller to user program while the motor is still running, let 
alone change the setting in user program or Android App. That is to say, if you want to connect 
controller to user program or try to do programming, please stop the motor first. 

This is the most important thing. 

 
 

Summary of Contents for Cheetah Series

Page 1: ...Permanent Motor Controller User s Manual V1 13 Kelly Cheetah series KLS S Light flexible Sinusoidal Permanent Magnet Motor Controllers User s Manual Devices Supported Rev1 13 Jan 2023 KLS4812S KLS7212...

Page 2: ...r 3 Wiring and Installation 6 3 1 Mounting the Controller 6 3 2 Connections 9 3 3 Installation Check List 14 Chapter 4 Programmable Parameters 15 4 1 Step 1 15 4 2 Step 2 20 4 3 Step 3 21 4 4 How to u...

Page 3: ...efficiency requirements in the application of DC brushless motor It uses high power MOSFET s and SVPWM and FOC to achieve efficiencies of up to 99 in most cases A powerful microprocessor brings in co...

Page 4: ...5 switch inputs which are activated by connection to 12V Default to throttle switch brake switch reversing switch forward switch and Boost switch 11 3 analog 0 5V inputs that default to throttle inpu...

Page 5: ...luminum housing for maximum heat dissipation and harsh environment 15 Rugged high current terminals and rugged aviation connectors for small signal 16 Thermal protection current cut back warning and s...

Page 6: ...Operating Temperature Range 0 to 70 MOSFET temperature Operating Temperature Range 40 to 100 MOSFET temperature Max Battery Current Configurable 2 4 Name Regulation The name regulation of Kelly BLDC m...

Page 7: ...m water and contaminants To ensure full rated output power the controller should be fastened to a clean flat metal surface with four screws Applying silicon grease or some other thermal conductive mat...

Page 8: ...Kelly KLS S Cheetah series Sinusoidal Permanent Motor Controller User s Manual V1 13 7 Figure 2 KLS 18S mounting holes dimensions dimensions in millimeters...

Page 9: ...Kelly KLS S Cheetah series Sinusoidal Permanent Motor Controller User s Manual V1 13 8 Figure 3 KLS 30S mounting holes dimensions dimensions in millimeters...

Page 10: ...ow This 12V only can be used for LED or switch signals 3 Boost and Brake analog regeneration mode used the same pin as pin2 When Boost is disabled in the user program the pin2 can be used as brake var...

Page 11: ...1 Temp Motor temperature sensor input Raddle 5 5V 5V supply output 40mA Purple 18 Hall A Hall phase A Yellow 17 Hall B Hall phase B Dark Green 16 Hall C Hall phase C Dark Blue Notes 1 All RTN pins are...

Page 12: ...al Permanent Motor Controller User s Manual V1 13 11 3 2 2 Wiring of KLS S Controller 3 2 2 1 Standard wiring of KLS S controller Figure 5 KLS S controller standard wiring F N R control Battery voltag...

Page 13: ...ntroller 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...

Page 14: ...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 con...

Page 15: ...tor is still running let alone change the settings in the user program Make sure the wire is connected correctly Turn the PWR switch on The Green LED stay on steadily and Red LED turns off when the co...

Page 16: ...in7 to batteries for Identification Angle operation Please download the instruction how to use Identification angle function from our website www kellycontroller com support php 4 1 Step 1 1 Low Volt...

Page 17: ...e This is normal Please reset the power supply again Then everything will be fine The motor is ready to be drived by the KLS controller Range 85 or 170 nothing else 6 TPS Low Err Hall active pedal if...

Page 18: ...tle effective ending point Suggestion Set according to the practical situation factory default is 80 5V 4 0V 14 Max output Fre Max output frequency Unit Hz Functional description It will affect the to...

Page 19: ...actory default is Disable 21 NTL H Pedal Neutral position High Pedal Disable Only useful when Three gears switch function is enabled If enable the controller will detect the current pedal position or...

Page 20: ...tus Forward Switch Foot Switch FWD_SW 12 REV_SW 14 Foot 15 Enable Disable OFF OFF x Neutral OFF ON x Reverse ON OFF x Forward ON ON x Neutral Disable Enable x OFF OFF Can t operate x ON OFF Can t oper...

Page 21: ...expected after finish the Identification angle operation please just choose Change Direction item Please click Write button to activate Change Direction function The motor direction will be what you...

Page 22: ...rottle regen mode type The regen will happen as long as the throttle is released completely Factory set is 0 2 NTL Brk NTL Braking Percent the percent of Neutral Braking in max braking Range 0 50 Only...

Page 23: ...gram It will help the motor change the direction of motor quickly after you shift throttle from 0V to 5V or from 5V to 0V Suggestion factory default is Disable 11 Compensation Per Tried to increase th...

Page 24: ...or Android App Tablet or Cell Phone KLS S controller is designed for BLDC motor with three hall sensors By default the speed sensor type is set at 2 from factory setting for KLS S controller 1 Please...

Page 25: ...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 Bluetooth conver...

Page 26: ...e shipment Your motor is different from the motor from controller supplier 5 Please fill 170 in the identification angle item And please click the write button The user program will give a pop up wind...

Page 27: ...picture of user program Please write 85 instead in identification angle by manual If there are no any error codes you can not write it back to 85 by manual Please wait longer time until the error code...

Page 28: ...connecting a load such as a contactor coil resistor or a horn across the controller s B and B terminals Remove any dirt or corrosion from the bus bar area The controller should be wiped with a moist...

Page 29: ...e will be regularly updated and published on the website Please Update your Configuration Software regularly You must uninstall the older version before updating Please try to use Identify function fo...

Page 30: ...pped but will restart when temperature falls below 80 2 4 Throttle error at power up Throttle signal is higher than the preset dead zone at Power On Fault clears when throttle is released 3 1 Reserved...

Page 31: ...or code is only valid for KLS 8080I controller Customers may read error codes in PC software or Android Tablet Contact Us Kelly Controls Inc Home Page http www KellyController com Download user manual...

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