Kelly KLS-H User manual

Kelly KLS-H Brushless Motor Controller User’s Manual
V1.10
Kelly KLS-H Brushless Motor
Controller User’s Manual
DevicesSupported:
KLS6022H
KLS6030H
KLS7215H
KLS7218H
KLS7222H
KLS7230H
KLS7245H
KLS7250H
KLS7275H
KLS8415H
KLS8422H
KLS8430H
KLS72501-8080H
KLS72601-8080H
KLS72701-8080H
KLS96301-8080H
KLS96401-8080H
KLS96501-8080H
KLS96601-8080H

Kelly KLS-H Brushless Motor Controller User’s Manual
V1.10
Rev.1.10
Jun.2017

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Contents
Chapter 1 Introduction........................................................................................................... 2
1.1 Overview............................................................................................................................. 2
Chapter 2 Features and Specifications.......................................................................... 3
2.1 General functions...............................................................................................................3
2.2 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......................................................................................................................10
3.3 Installation Check List.....................................................................................................14
Chapter 4 Programmable Parameters..........................................................................15
4.1 Step 1 ................................................................................................................................18
4.2 Step 2 ................................................................................................................................20
4.3 Step 3 ................................................................................................................................21
4.4 How to use Identification angle operation function......................................................22
Chapter 5 Maintenance.......................................................................................................26
5.1 Cleaning ............................................................................................................................27
5.2 Configuration ....................................................................................................................27
Table 1: ERROR CODES ......................................................................................................28
Contact Us:...................................................................................................................................30

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Chapter 1 Introduction
1.1 Overview
The biggest difference is KLS-H is a waterproof type controller by default.It is IP66 rating.
This manual introduces the Kelly 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.But KLS-8080H model is only IP54 rating.
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-H motor
controller must be based on hall sensors type.KLS-H 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 to 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.TheAPP 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.Customers can
connect the KLS controller to Android App in Android Phone if they order Bluetooth converter
from Kelly Controls.
KLS-H has a friendly I/O terminals for customers to hook up the batteries and motor easily.

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Chapter 2 Features and Specifications
2.1 Generalfunctions
(1) Extended fault detection and protection. Customers can read the error message in PC
software or AndroidAPP also.
(2) Monitoring battery voltage. It will stop driving if the battery voltage is too high and it will
progressively cut back motor drive power as battery voltage drops until it cuts out
altogether at the preset “Low Battery Voltage”setting.
(3) Built-in current loop and over current protection.
(4) Configurable motor temperature protection range.
(5) Current cutback at low temperature and high temperature to protect battery and controller.
The current begins to ramp down at 90℃ case temperature, shutting down at 100℃.
(6) The controller keeps monitoring battery recharging voltage during regen braking.
(7) Maximum reverse speed and forward speed can be configured between 20% and 100%
respectively and separately.
(8) A 4pin connector to RS232 port and a Z-TEK USB to RS232 cable allows for configuration,
programming and software upgrades using the tablet which must be based on Android OS
now.People can do the same things on PC software by using a standard USB to RS232
cable instead.
(9) Provision of a +5 volt and +12 volt output to supply various kinds of 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 to throttle input,Brake analog input and motor
temperature input
(12) Copy signal of one of hall sensors.
(13) Configurable boost switch. Enables the maximum output power achievable if the switch is
turned on.The effect is the same as full throttle position even if you don’t turn throttle at all.
(14) 12V brake switch input used different port from motor temperature sensor.You can use
both brake switch and motor temperature sensor functions at the same time on the latest
version.Pin 25 is 12V brake switch input port.Pin1 is motor temperature sensor input port.
(15) Optional joystick throttle. A bi-symmetrical 0-5V signal for both forward and reversing.
(16) Configurable motor over-temperature detection and protection with the recommended
thermistor KTY84-130/150 or KTY83-122.
(17) 3 hall position sensor inputs. Open collector, pull up provided.
(18) Brake analog regen mode.This regen mode doesn't need brake switch to support any
more.Only available from software version 0106 or advanced version.
(19) Enhanced regen brake function. A novel ABS technique provides powerful and smooth
regen.The regen can happen at any speeds until zero speed.
(20) KLS-H controller included the fuse on the case.Not shunt is attached.
(21) Cruise control.Only can be activated in forward direction.
(22) KLS-H can support Broadcast type CAN Bus function.It is 250Kbps.CAN bus is not
included in KLS-H controller by default.CAN bus is only an optional function for KLS-H.
CAN ID can be changed in the latest user program also.

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(23)Bluetooth function.Required a small Bluetooth converter which needs to be purchased in
addition from our website.This small converter is only useful for KLS controller.
(24)Can support three speed function on the latest version.
Caution! The regen is not a safe function.Usually you may use the mechanical brake.
2.2 Features
1) Intelligence with powerful microprocessor.
2) Synchronous rectification, ultra low drop, fast SVPWM and FOC to achieve very high
efficiency.
3) Electronic reversing.
4) Voltage monitoring on 3 motor phases, bus, and power supply.
5) Voltage monitoring on voltage source 12V and 5V.
6) Current sense on all 3 motor phases.
7) Current control loop.
8) Hardware over current protection.
9) Hardware over voltage protection.
10) Configurable limit for motor current and battery current.
11) Low EMC.
12) Battery protection: current cutback, warning and shutdown at configurable high and low
battery voltage.
13) Rugged aluminum housing for maximum heat dissipation and harsh environment.
14) Rugged high current terminals, and rugged aviation connectors for small signal.
15) Thermal protection: current cut back, warning and shutdown on high temperature.
16) Controller can do auto_Identification angle for different degrees of hall sensors.
17) Configurable high pedal protection: the controller will not work if high throttle is detected at
power on.
18) Current multiplication: Take less current from battery, output more current to motor.
19) Easy installation: 3-wire potentiometer will work.
20) Standard PC/Laptop computer to do programming.There is one more choice for customers
to program KLS controller.Standard Tablet withAndroid OS to do programming.Need a
Z-TEK USB TO RS232 cable for connecting the controller to App program in Tablet.
21) User program provided. Easy to use. No cost to customers.
22) Support motors with any number of poles.
23)Up to 70,000 electric RPM standard. (Electric RPM = mechanical RPM * motor pole
pairs;Motor pole pairs=Motor poles/2).
24) KLS-H:Dust and water protected under sealed condition,IP66
25) KLS-8080H.The protection rating is IP54.

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2.3 Specifications
•Frequency of Operation: 10KHz or 20KHz.
•Standby Battery Current: < 0.5mA.
•5V or 12V Sensor Supply Current: 40mA.
•Controller supply voltage range: PWR, 18V to 90V for controllers rated equal or lower than
72V.The PWR can be 96V batteries for KLS96xxx-8080H model.So All KLS-H and KLS-8080H
model are non isolated type controllers.
•Supply Current, PWR, 30mATypical.
•Configurable battery voltage range, B+. Max operating range: 18V to 1.25*Nominal Voltage.
•Standard Throttle Input: 0-5 Volts(3-wire resistive pot), 1-4 Volts(hall active throttle).
•Throttle Input: 0-5 Volts. Can use 3-wire pot to produce 0-5V signal.
•
•Full Power 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 motor controllers:
KLS 72 30H
KLS: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.
72:72V batteries.
H:The motor controller included a plastic cover with a fuse.And KLS-H is IP66 rating
without filling the silica gel by default.But KLS-8080H is IP54 rating.
C:BroadCast type CAN bus protocol.
Kelly KLSH Brushless Motor Controller
Model
30 seconds
Current(Amp)
Continuous
Current(Amp)
Voltage(Volt)
KLS6022H
220
88
24-60
KLS6030H
350
120
24-60
KLS7215H
150
60
24-72
KLS7218H
200
80
24-72
KLS7222H
220
80
24-72
KLS7230H
300
100
24-72
KLS7245H
350
140
24-72
KLS7250H
400
160
24-72
KLS7275H
500
200
24-72
KLS8415H
150
60
24-84
KLS8422H
220
80
24-84
KLS8430H
300
100
24-84

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KLS72501-8080H
500
200
24-72
KLS72601-8080H
600
240
24-72
KLS72701-8080H
700
280
24-72
KLS96301-8080H
300
120
24-96
KLS96401-8080H
400
160
24-96
KLS96501-8080H
500
200
24-96
KLS96601-8080H
600
240
24-96
1.60V model: range of the batteries voltage is 18V-80V.
2.72V model: range of the batteries voltage is 18V-90V.
3.84V model: range of the batteries voltage is 18V-105V.
4.96V model: range of the batteries voltage is 18V-120V
Chapter 3 Wiring and Installation
3.1 Mounting the Controller
The controller can be oriented in any position which should be as clean and dry as possible,
and if necessary, shielded with a cover to protect it from 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 material to
contact surface will enhance thermal performance.
Proper heat sinking and airflow are vital to achieve the full power capability of the controller.
The case outline and mounting holes’ dimensions are shown in Figure 1,2,3,4.

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Figure 1: KLS7215H KLS7218H KLS6022H,KLS6030H,KLS7230H mounting holes’ dimensions
(dimensions in millimeters)

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Figure 2: KLS7245H mounting holes’ dimensions (dimensions in millimeters)

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Figure 3: KLS7250H mounting holes’ dimensions (dimensions in millimeters)

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Figure 4: KLS7275H mounting holes’ dimensions (dimensions in millimeters)

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Figure 5: KLS72xxx-8080H KLS96xxx-8080H mounting holes’ dimensions (dimensions in
millimeters)

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3.2 Connections
3.2.1 Pin definition of KLS-H Controller
1,The switch signal is valid to 12V on pin11
2,12V capacity is low.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 variable regen
mode.When Boost is enabled,the brake analog regen mode is inactivated automatically.Both
Boost and Brake variable regen mode can not be used at the same time.
Figure 6: waterproof connector
DJ7091Y-2.3-11 Pin Definition
(14) REV_SW: Reverse switch input. Orange
(6) RTN: Signal return or power supply return. Black
(12) FWD: Forward switch White
(11) 12V:12V Source Red
(25) 12V brake switch. Yellowish

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(9) Relay: Main contactor driver. Blue
(33)CAN-H:Green(Optional function)
(7) PWR: Controller power supply (input). Pink
(34)CAN-L:Dark Gray(Optional function)
DJ7091Y-2.3-21 Pin Definition
(15) Micro_SW: Throttle switch input. Gray
(3) Throttle: Throttle analog input, 0-5V. Dark Green
(1) Temp: Motor temperature sensor input. Raddle.
(20) RTN: Signal return. Black
(8) Meter: Copy signal of hall sensors. Dark Blue
(4) 5V: 5V supply output, <40mA. Purple
(2) Brake_AN：Brake variable regen or Boost function. Brown
DJ7061Y-2.3-21 Pin Definition
(21) RTN:Signal return. Black
(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 connected.
2. Meter function is to copy either of hall sensors.
3. Switch to 12V is active. Open switch is inactive.
Caution:
• Do not apply power until you are certain the controller wiring is correct and has been
double checked. Wiring faults will damage the controller.
• Ensure that the B- wiring is securely and properly connected before applying power.
• The preferred connection of the system contactor or circuit breaker is in series with the B+
line.
• All contactors or circuit breakers in the B+ line must have precharge resistors across their
contacts. Lack of even one of these precharge resistors may severely damage the controller
at switch-on.

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3.2.2 Standard Wiring of KLS-HC Controller
Figure 6: KLS-H controller standard wiring
(Battery voltage can be used for controller supply)

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3.2.3 Optional wiring of KLS-HC controller
The 12V input signal of the pin supplies the second braking function of the controller.
Figure 7: Wiring of brake switch(12V): 12V is provided by external source.
Figure 8: Wiring of brake switch(12V): 12V is provided by KLS-D controller on pin11
Figure 9: Wiring diagram for motor temperature sensor
NOTE:The motor temperature sensor and brake switch used the different I/O port on latest

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version.Both functions can be used at the same time.KLS controller can support KTY84-150
and KTY84-130 thermistors.
3.2.4 Communication Port
A4pin connector to RS232 port is provided to communicate with host computer for calibration and
configuration.
Figure 10: RS232 Interface on 4pin connector to RS232 converter
Figure 11：SM-4P connector for communication interface on KLS-H controller
3.3 Installation Check List
Before operating the vehicle, complete the following checkout procedure. Use buzzer code
as a reference as listed in Table 1.
Caution:
• Put the vehicle up on blocks to get the drive wheels off the ground before beginning these
tests.
• Do not allow anyone to stand directly in front of or behind the vehicle during the checkout.
• Make sure the PWR switch and the brake is off
• Use well-insulated tools.

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•Make sure the wire is connected correctly
•Turn the PWR switch on.
•The fault code will be detected automatically at restart.
•With the brake switch open, select a direction and operate the throttle. The motor should
spin in the selected direction. Verify wiring or voltage and the fuse if it does not. The motor
should run faster with increasing throttle. If not, refer to the Table 1 code, and correct the
fault as determined by the fault code.
•Take the vehicle off the blocks and drive it in a clear area. It should have smooth
acceleration and good power.
Chapter 4 Programmable Parameters
KLS Configuration program allow users to set parameters according to the vehicle actual
working environment so as to be at its best.
The default parameters of the controller are not recommended for all applications. Make
sure set the proper parameters before making any test to avoid danger.
Customers can do program on PC software or Android App.The Android Tablet is
prefered.First of all,people need to do Identification angle function for KLS controller before
running the motor.The controller needs to be connected to batteries,motor and throttle before
Identification operation.That is to say,it is not enough to connect only power supply(PWR=pin7)
to batteries for Identification Angle operation.