Kelly KLS2418ND, User Manual

Page 1: ...nual Devices Supported KLS2412ND KLS4812ND KLS7212ND KLS7260NG KLS2412N KLS4812N KLS7212N KLS7275NC KLS2418ND KLS4818ND KLS7215ND KLS72100NC KLS2418N KLS4818N KLS7215N KLS72120NC KLS2430ND KLS4830ND K...

Page 2: ...Features 4 2 3 Specifications 5 2 4 Name Regulation 5 Chapter 3 Wiring and Installation 6 3 1 Mounting the Controller 6 3 2 Connections 15 3 3 Installation Check List 19 Chapter 4 Programmable Paramet...

Page 3: ...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...

Page 4: ...hall sensors 10 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 t...

Page 5: ...current cutback warning and shutdown at configurable high and low battery voltage 13 Aluminum based PCB board with heat sink plate on the bottom of controller 14 Waterproof connectors for small signa...

Page 6: ...waveform which is supposed to work with BLDC motor with three hall sensors All KLS controllers can do regen brake function by default 24 24V batteries N The motor controller included a plastic cover...

Page 7: ...Peak Current 2 Minutes Continuous Current KLS4860NG 36 48V 27 60V 400A 160A 240A KLS4875NC 36 48V 27 60V 500A 200A 300A KLS48100NC 36 48V 27 60V 600A 240A 360A KLS48120NC 36 48V 27 60V 700A 280A 420A...

Page 8: ...ller User s Manual V2 9 7 Figure 1 KLS2412ND KLS4812ND KLS7212ND KLS7215ND mounting holes dimensions dimensions in millimeters B B U V W M5 Bolts Figure 2 KLS2412N KLS4812N KLS7212N KLS7215N mounting...

Page 9: ...nusoidal Brushless Permanent Magnet Motor Controller User s Manual V2 9 8 Figure 3 KLS2418ND KLS2430ND KLS2435ND KLS4818ND KLS4830ND KLS4835ND KLS7218ND KLS7222ND mounting holes dimensions dimensions...

Page 10: ...elly KLS N Sinusoidal Brushless Permanent Magnet Motor Controller User s Manual V2 9 9 Figure 4 KLS2418N KLS2430N KLS4818N KLS4830N KLS7218N KLS7222N mounting holes dimensions dimensions in millimeter...

Page 11: ...Kelly KLS N Sinusoidal Brushless Permanent Magnet Motor Controller User s Manual V2 9 10 Figure 5 KLS7230ND KLS7235ND mounting holes dimensions dimensions in millimeters...

Page 12: ...Kelly KLS N Sinusoidal Brushless Permanent Magnet Motor Controller User s Manual V2 9 11 Figure 6 KLS7230N mounting holes dimensions dimensions in millimeters...

Page 13: ...Kelly KLS N Sinusoidal Brushless Permanent Magnet Motor Controller User s Manual V2 9 12 Figure 7 KLS4860NG KLS7260NG mounting holes dimensions dimensions in millimeters B B U V W M8...

Page 14: ...inusoidal Brushless Permanent Magnet Motor Controller User s Manual V2 9 13 Figure 8 KLS4875NC KLS7275NC KLS48100NC KLS72100NC KLS48120NC KLS72120NC mounting holes dimensions dimensions in millimeters...

Page 15: ...ushless Permanent Magnet Motor Controller User s Manual V2 9 14 Figure 9 With Aluminum Liquid Cooling Heatsink at the bottom Only for 400A and above controllers mounting holes dimensions dimensions in...

Page 16: ...4 CAN bus is not included in KLS N controller by default When boost is disabled in user program pin2 is used as brake analog regen mode When boost is enable pin2 is used for boost function You may not...

Page 17: ...Hall B Hall phase B Dark Green 16 Hall C Hall phase C Dark Blue Notes 1 All RTN pins are internally connected 2 Meter function is to copy either of hall sensors 3 Switch to 12V is active Open switch...

Page 18: ...f 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 s...

Page 19: ...ng 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...

Page 20: ...e checkout Make sure the PWR switch and the brake is off Use well insulated tools Make sure the wire is connected correctly Turn the PWR switch on The fault code will be detected automatically at rest...

Page 21: ...n7 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 T...

Page 22: ...ly 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 lower than the value report the fault of TPS...

Page 23: ...gh Range 60 95 Functional description Set throttle 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...

Page 24: ...ctive output the controller will report fault and not operate Suggestion Set according to the practical situation factory default is Disable 21 NTL H Pedal Neutral position High Pedal Disable Only use...

Page 25: ...oot switch is turned off Please see figure 4 1 Suggestion Set according to the practical situation factory default is Disable Configuration Pin Status Running Status Forward Switch Foot Switch FWD_SW...

Page 26: ...elp the motor stop on the downhill But usually this function only helps motor stop rolling back too fast Suggestion factory default is Disable 28 Change Direction If the direction is not what you expe...

Page 27: ...less for KLS N or KLS M model 4 3 Step 3 1 RLS_TPS Brk RLS TPS Braking Percent the percent of Releasing Pedal BRK in max braking Range 0 50 This is used to adjust the regen current of releasing thrott...

Page 28: ...for PID adjustment If you think the acceleration performance is very very strong please adjust them to a lower value respectively 10 Change Dir brake Value range Enable and Disable It is only useful w...

Page 29: ...is normal This item is only useful for internal calculation for MCU 246 is about 11 degrees in environment 4 4 How to use Identification angle operation function We must do Identification angle opera...

Page 30: ...Kelly KLS N Sinusoidal Brushless Permanent Magnet Motor Controller User s Manual V2 9 29 2 Please connect the controller to user program by using an USB to RS232 cable and SM 4A DB9 RS232 Converter...

Page 31: ...B 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 W...

Page 32: ...g Because the 85 means this controller finished the identification angle operation with the motor in factory before shipment Your motor is different from the motor from controller supplier 5 Please fi...

Page 33: ...codes such as Identify error hall err etc please return to the first picture of user program Please write 85 instead in identification angle by manual If there are no any error codes you can not writ...

Page 34: ...e the connections to the bus bars if fitted are tight To avoid physically stressing the bus bars use two well insulated wrenches 5 2 Configuration You can configure the controller with a host computer...

Page 35: ...n for motor and hall sensors in the user program Table 1 Error Codes Buzzer Error Codes Code Explanation Solution 1 1 Automatic error identification 1 Wrong wiring of motor phase line or hall Please s...

Page 36: ...t condition like a temporary over current momentarily high or low battery voltage This can happen during normal operation 3 3 Hall throttle is open or short circuit When the throttle is repaired a res...

Page 37: ...et Motor Controller User s Manual V2 9 36 Contact Us Kelly Controls Home Page http www KellyController com Download user manual instructions and user program www kellycontroller com support php E mail...