Kelly KLS4812S, User Manual

Page 1: ...KLS S Brushless Motor Controller User s Manual V1 10 Kelly KLS S Brushless Motor Controller User s Manual Devices Supported Rev1 10 Feb 2019 KLS4812S KLS7212S KLS6018S KLS7230S KLS6030S KLS7218S KLS6...

Page 2: ...3 Specifications 5 2 4 Name Regulation 5 Chapter 3 Wiring and Installation 6 3 1 Mounting the Controller 6 3 2 Connections 10 3 3 Installation Check List 14 Chapter 4 Programmable Parameters 15 4 1 St...

Page 3: ...quirements 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 an...

Page 4: ...nnection 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 input Brake analog input and motor temperature...

Page 5: ...on and harsh environment 15 Rugged high current terminals and rugged aviation connectors for small signal 16 Thermal protection current cut back warning and shutdown on high temperature 17 Controller...

Page 6: ...o 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 motor controllers KLS 72 30S KLS...

Page 7: ...ants 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 material to contact sur...

Page 8: ...Kelly KLS S Brushless Motor Controller User s Manual V1 10 7 Figure 2 KLS6018S mounting holes dimensions dimensions in millimeters...

Page 9: ...Kelly KLS S Brushless Motor Controller User s Manual V1 10 8 Figure 3 KLS7218S mounting holes dimensions dimensions in millimeters...

Page 10: ...Kelly KLS S Brushless Motor Controller User s Manual V1 10 9 Figure 4 KLS6030S KLS6035S KLS7230S mounting holes dimensions dimensions in millimeters...

Page 11: ...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 variable regen...

Page 12: ...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 internally c...

Page 13: ...Motor Controller User s Manual V1 10 12 3 2 2 Wiring of KLS S Controller 3 2 2 1 Standard wiring of KLS S controller Figure 6 KLS S controller standard wiring F N R control Battery voltage can be used...

Page 14: ...dard 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 braking funct...

Page 15: ...12V is provided by KLS S controller on pin11 Figure 10 Wiring diagram for motor temperature sensor 3 2 3 Communication Port A 4pin connector to RS232 port is provided to communicate with host computer...

Page 16: ...ser program while the motor 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 L...

Page 17: ...se download the instruction how to use Identification angle function from our website www kellycontroller com support php 4 1 Step 1 1 Low Volt The min voltage of reporting this fault Range 18 90 Cont...

Page 18: ...e 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 Type Range 0 20 7 TPS High Err Hall active pedal if higher than the value...

Page 19: ...e practical situation factory default is 80 5V 4 0V 14 Max output Fre Max output frequency Unit Hz Functional description It will affect the top speed of the motor Suggestion Set according to the prac...

Page 20: ...Only useful when Three gears switch function is enabled If enable the controller will detect the current pedal position or signal When the switch is in neutral poistion If the throttle got effective...

Page 21: ...x OFF OFF Can t operate x ON OFF Can t operate x ON ON Reverse x OFF ON Forward Disable Disable x OFF x Forward x ON x Reverse Note X means can be on or off Figure 4 2 24 Boost If enabled the controll...

Page 22: ...nction The motor direction will be what you expected after the power supply is reset Suggestion factory default is Disable 4 2 Step 2 1 Motor Nominal Curr When the controller is doing identification a...

Page 23: ...the percent of Neutral Braking in max braking Range 0 50 Only useful when you enable Three gears switch in user program The regen will happen when you turn F N R switch from Forward or backward to Neu...

Page 24: ...is Disable 11 Compensation Per Tried to increase the current usage during Anti Slip operation 12 IVT BRK MAX and IVT BRK MIN These two items are only useful when Joystick function is enabled in the u...

Page 25: ...three hall sensors By default the speed sensor type is set at 2 from factory setting for KLS S controller 1 Please hook up the controller for identification angle operation according to the wiring dia...

Page 26: ...ird 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 converter for progr...

Page 27: ...ur 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 window which show...

Page 28: ...er 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 codes occur Pleas...

Page 29: ...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 rag Make sure...

Page 30: ...ularly 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 for motor and h...

Page 31: ...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 3 2 Internal...

Page 32: ...ly 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 instructions...