Kelly KLS-S User manual

Kelly KLS-S Brushless Motor Controller User’s Manual V1.9
Kelly KLS-S Brushless Motor
Controller User’s Manual
Devices Supported:
Rev1.9
Feb.2016
KLS4812S
KLS7212S
KLS6018S
KLS7230S
KLS6025S
KLS7218S
KLS6030S
KLS7240S

Kelly KLS-S Brushless Motor Controller User’s Manual V1.9
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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...................................................................................................................... 11
3.3 Installation Check List......................................................................................................16
Chapter 4 Programmable Parameters................................................................ 17
4.1 Step 1................................................................................................................................. 17
4.2 Step 2................................................................................................................................. 21
4.3 Step 3................................................................................................................................. 22
Chapter 5 Maintenance..........................................................................................23
5.1 Cleaning.............................................................................................................................23
5.2 Configuration.....................................................................................................................23
Table 1: LED CODES................................................................................................ 24
Contact Us:..................................................................................................................26

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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, LLC.
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 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.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.

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Chapter 2 Features and Specifications
2.1 General functions
(1) Extended fault detection and protection. The LED flashing pattern indicates the fault
sources.Customers can read the error code in PC software or Android Tablet 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
on KLS controller.Only available from software version 0106 or advanced version.KLS
controller can not support reflashing firmware by default.
(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) Cruise control.Only can be activated in reversing direction.
(21) 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.

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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) LED fault code.
13) Battery protection: current cutback, warning and shutdown at configurable high and low
battery voltage.
14) Rugged aluminum 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 shutdown on high temperature.
17) Controller can do auto_Identification angle for different degrees of hall sensors.
18) Configurable high pedal protection: the controller will not work if high throttle is detected at
power on.
19) Current multiplication: Take less current from battery, output more current to motor.
20) Easy installation: 3-wire potentiometer will work.
21) Standard PC/Laptop computer to do programming.There is one more choice for customers
to program KLS controller.Standard Tablet with Android OS to do programming.Need a
Z-TEK USB TO RS232 cable for connecting the controller to App program in Tablet.
22) User program provided. Easy to use. No cost to customers.
23) Support motors with any number of poles.
24) Up to 70,000 electric RPM standard. (Electric RPM = mechanical RPM * motor pole
pairs;Motor pole pairs=Motor poles/2).

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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.
•Supply Current, PWR, 30mA Typical.
•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.
•Main Contactor Coil Driver<2A.
•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 30S
KLS:Kelly BLDC motor controller based on sinusoidal waveform which is supposed to
work with BLDC motor with three hall sensors.
72:72V batteries
S:Mini case for the controller
Kelly KLS-S Brushless Motor Controller
Model
10 seconds
Current(Amp)
Continuous
Current(Amp)
Voltage(Volt)
KLS4812S
120
50
24-48
KLS7212S
120
50
24-72
KLS6018S
240
100
24-60
KLS6025S
300
120
24-60
KLS6030S
350
150
24-60
KLS7218S
200
80
24-72
KLS7230S
300
120
24-72
KLS7240S
350
150
24-72
1.48V model: range of the battery voltage is 24V-48V.
1.60V model: range of the battery voltage is 24V-60V.
3.72V model: range of the battery voltage is 24V-72V.

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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 1,2,3,4,5.
Figure 1:KLS4812S KLS7212S mounting holes’ dimensions (dimensions in millimeters)

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Figure 2:KLS6018S mounting holes’ dimensions (dimensions in millimeters)

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Figure 3:KLS7218S mounting holes’ dimensions (dimensions in millimeters)

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Figure 4:KLS6025S mounting holes’ dimensions (dimensions in millimeters)

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Figure 5:KLS6030S KLS7230S mounting holes’ dimensions (dimensions in millimeters)

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Figure 6:KLS7240S mounting holes’ dimensions (dimensions in millimeters)

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3.2 Connections
3.2.1 Pin definition of KLS-S Controller
Figure 7: 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
(9) Relay: Main contactor driver. Blue
(7) PWR: Controller power supply (input). Pink
(25) 12V brake switch. Yellowish

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DJ7091Y-2.3-21 Pin Definition
(15) Micro_SW: Throttle switch input. Gray
(3) Throttle: Throttle analog input, 0-5V. Green
(1) Temp: Motor temperature sensor input. Raddle.
(20) RTN: Signal return. Black
(8) Meter: Copy signal of hall sensors. Dark Gray
(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 Wiring of KLS-S Controller
3.2.2.1 Standard wiring of KLS-S controller
Figure 8: KLS-S controller standard wiring
(Battery voltage can be used for controller supply)

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3.2.2.2 Optional wiring of KLS-S controller
The 12V input signal of the pin supplies the second braking function of the controller.
Figure 9: Wiring of brake switch(12V): 12V is provided by external source.
Figure 10: Wiring of brake switch(12V): 12V is provided by KLS-S controller on pin11
Figure 11: 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
configuration.

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Figure 12: RS232 Interface on 4pin connector to RS232 converter
Figure 13：SM-4P connector for communication interface on KLS-S controller
3.3 Installation Check List
Before operating the vehicle, complete the following checkout procedure. Use LED 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.
•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
controller operates normally. If this does not happen, check continuity of the PWR and
return.
•The fault code will be detected automatically at restart.
•With the brake switch open, select a direction and operate the throttle. The motor should

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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 LED 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.
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: The min voltage of reporting this fault - Range 18~90
Controller will not operate when battery voltage is near the value so as to protect battery.
Suggestion: Set according to the practical situation.By default,it is set at 18V.
(2)Over Volt: The max voltage of reporting this fault - Range 18~90
Controller will not operate when battery voltage is higher than the value so as to protect battery
and controller.
Suggestion: Set according to the practical situation.
By default,It is 60V for 48V controller.It is 80V for 60V controller.It is 90V for 72V controller.
Controller Rated voltage
Under Voltage Range (V)
Over Voltage Range(V)
48V
18~60
18~60
60V
18~80
18~80
72V
18~90
18~90
Figure 4.1
(3)Current Percent: Phase Current Percent. Range: 20~100
Functional description: The max motor current is (The Value * Peak Current of the Controller).
Suggestion: Factory default is 100%.

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(4)Battery Limit: Battery Limit Current, Limit the max value of Battery Current. Range: 20~100
Functional description: Set max battery current so as to protect battery. A lower value means a
lower battery output current and better protective effect. But excessively low value will affect
acceleration.
Suggestion: Factory default is 100%.
(5)Identification Angle: Please download the instruction to how to use Identification angle
function from the website.
www.kellycontroller.com/support.php
If you can read 85 in Identification Angle item,that is to say,the system is stable and
normal.Please fill in 170 for Identification Angle item in user program.Then
please click Write button in user program.Please wait a few seconds before restart the power
supply.You will see some info on Monitor screen after power supply is
reset.If you see Reset error on the Monitor screen,that is to say,the auto_Identification is
finished.You can see 85 in the Identification Angle item again.And the controller will
blink error code.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 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, report the fault of TPS Type. Range:
80~100
As you may know,the output of hall throttle from Kelly is about from 0.86V to 4.2V.
Our controller will report 3.3 error code if the output of hall throttle is below 0.5V or above 4.5V
by default.
The controller will think the hall throttle is shorted or damaged if the output is beyond the range
from 0.5V to 4.5V.
You can adjust the threshold voltage below or above 0.5V.The controller will report the 3.3 code
to protect the system according to different types of hall throttle.
Because there are many different hall throttle suppliers in the world.The initial output can not be
always in the range of 0.5V to 4.5V.
But it doesn't make any differences if you choose 0-5V or 3-wire pot for the throttle type.That is
to say,these two settings are only useful for hall active throttle or pedal when you chose throttle
type at 2.
As the same goes,it is valid to adjust the high threshold voltage above 4.5V or below 4.5V.
Usually the hall output voltage is 4.2V Max.If you adjust it to lower value which is near 4.2V,it
may trigger the error code in normal way.
(8)TPS Type: TPS Type, 1:0-5V 3-wire 0-5K pot,5K is normal,2K-20K can be used;2:Hall active
throttle or pedal. Range: 1~2

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(9)TPS Dead Low: TPS Dead Zone Low. Range: 5~40
Functional description: Set throttle effective starting point
Suggestion: Set according to the practical situation, factory default is 20%*5V=1.0V.
(10)TPS Dead High: TPS Dead Zone High. Range: 60~95
Functional description: Set throttle effective ending point
Suggestion: Set according to the practical situation, factory default is 80%*5V=4.0V.
(11)Brake sensor type:Brake sensor type for brake variable regen mode:
1:0-5V 3-wire 0-5K pot,5K is normal,2K-20K can be used;2:Hall active throttle or pedal. Range:
1~2
(12)Brake sensor Dead Low: Brake sensor Dead Zone Low. Range: 5~40
Functional description: Set throttle effective starting point
Suggestion: Set according to the practical situation, factory default is 20%*5V=1.0V.
(13)Brake sensor Dead High: Brake sensor Dead Zone High. 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:Hz
Functional description:It will affect the top speed of the motor.
Suggestion: Set according to the practical situation, factory default is 1000Hz.Please don’t set it
1000Hz above.
(15)Max Speed: Max Speed [rpm]. Range: 0~15000 By default,it is set at 4000.Software
version 0109 can support 15000RPM settings in user program.
(16)Max Fwd Speed %: The forward speed of the percentage of maximum speed. Range:
20~100 By default,it is set at 100%
(17)Max Rev Speed %: The reverse speed of the percentage of maximum speed. Range:
20~100 By default,it is set at 100%
(18)PWM Frequency: Frequency of PWM operation. Unit:KHz
Functional description:20KHz is better for hub motor with strict quiet control.
Suggestion: Set according to the practical situation, factory default is 20KHz.Please don’t set it
20KHz above.
Value Range:10KHz or 20KHz
(19)Start-up H-Pedal:
Value range: Enable and Disable
Functional description: If enabled, the controller will detect the current pedal status at power up.