Kelly KLS2418ND User manual

Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9
Kelly KLS-N Sinusoidal Brushless
Permanent Magnet Motor Controller
User’s Manual
Devices Supported:
KLS2412ND
KLS4812ND
KLS7212ND
KLS7260NG
KLS2412N
KLS4812N
KLS7212N
KLS7275NC
KLS2418ND
KLS4818ND
KLS7215ND
KLS72100NC
KLS2418N
KLS4818N
KLS7215N
KLS72120NC
KLS2430ND
KLS4830ND
KLS7218ND
KLS2430N
KLS4830N
KLS7218N
KLS2435ND
KLS4835ND
KLS7222ND
KLS4860NG
KLS7222N
KLS4875NC
KLS7230ND
KLS48100NC
KLS7230N
KLS48120NC
KLS7235ND
Rev. 2.9
Feb. 2023

Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9
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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 ....................................................................................................15
3.3 Installation Check List....................................................................................19
Chapter 4 Programmable Parameters.......................................................................20
4.1 Step 1 ..............................................................................................................20
4.2 Step 2 ..............................................................................................................25
4.3 Step 3 ..............................................................................................................26
4.4 How to use Identification angle operation function.......................................28
Chapter 5 Maintenance.............................................................................................33
5.1 Cleaning..........................................................................................................33
5.2 Configuration..................................................................................................33
Table 1: Error Codes....................................................................................................34
Contact Us:..................................................................................................................36

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Chapter 1Introduction
1.1 Overview
The biggest difference is KLS-N 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.
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-N motor
controller must be based on hall sensors type. KLS-N 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. Customers
can connect the KLS controller to Android App in Android Phone if they order Bluetooth
converter from Kelly Controls.
KLS-N has a friendly I/O terminals for customers to hook up the batteries and motor easily.
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.

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Chapter 2 Features and Specifications
2.1 General functions
(1) Extended fault detection and protection. Customers can read the error message in PC
software or Android APP 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.
(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-N controller doesn’t include the fuse and shunt on the case any more by default.
(21) Cruise control. Only can be activated in forward direction.
(22) KLS-N can support Broadcast type CAN Bus function. It is 250Kbps.CAN bus is not

Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9
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included in KLS-N controller by default.CAN bus is only an optional function for KLS-N.
(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.
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) Aluminum based PCB board with heat sink plate on the bottom of controller.
14) Waterproof 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) Dust and water protected under sealed condition,IP66

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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.
•Supply Current, PWR, 30mATypical.
•Configurable battery voltage range, B+.
•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:
KLS2412ND
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.
24: 24V batteries
N: The motor controller included a plastic cover. And KLS-N is IP66 rating without filling
the silica gel by default. KLS-N used cast aluminum box as body protection.
D: stands for conductive
Kelly KLS-N - Sinusoidal Brushless Permanent Magnet Motor Controller
Model
Nominal
Voltage
Max Operating
Voltage
Peak Current**
1 Minute
Continuous
Current
KLS2412ND
12-24V
9-32V
140A
Up to 100A *
KLS2412N
12-24V
9-32V
140A
60A
KLS2418ND
12-24V
9-32V
220A
Up to 125A *
KLS2418N
12-24V
9-32V
220A
80A
KLS2430ND
12-24V
9-32V
280A
Up to 160A *
KLS2430N
12-24V
9-32V
280A
90A
KLS2435ND
12-24V
9-32V
320A
Up to 165A*
KLS4812ND
36-48V
27-60V
140A
Up to 100A *
KLS4812N
36-48V
27-60V
140A
60A
KLS4818ND
36-48V
27-60V
220A
Up to 125A *
KLS4818N
36-48V
27-60V
220A
80A
KLS4830ND
36-48V
27-60V
280A
Up to 160A *

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KLS4830N
36-48V
27-60V
280A
90A
KLS4835ND
36-48V
27-60V
320A
Up to 165A*
KLS7212ND
48-72V
36-86V
140A
Up to 100A *
KLS7212N
48-72V
36-86V
140A
50A
KLS7215ND
48-72V
36-86V
200A
Up to 105A *
KLS7215N
48-72V
36-86V
200A
60A
KLS7218ND
48-72V
36-86V
220A
Up to 125A *
KLS7218N
48-72V
36-86V
220A
80A
KLS7222ND
48-72V
36-86V
250A
Up to 130A *
KLS7222N
48-72V
36-86V
250A
85A
KLS7230ND
48-72V
36-86V
280A
Up to 150A *
KLS7230N
48-72V
36-86V
280A
90A
KLS7235ND
48-72V
36-86V
320A
Up to 165A *
Note: *Depends on conductive heat sink
**Peak current can be prolonged with additional heat sink, easily over 2 minutes.
Kelly KLS-N - Sinusoidal Brushless Permanent Magnet Motor Controller
Model
Nominal
Voltage
Max Operating
Voltage
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
KLS7260NG
48-72V
36-86V
400A
160A-240A
KLS7275NC
48-72V
36-86V
500A
200A-300A
KLS72100NC
48-72V
36-86V
600A
240A-360A
KLS72120NC
48-72V
36-86V
700A
280A-420A
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 below.

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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 holes’dimensions
(dimensions in millimeters) B+,B-,U,V,W:M5 Bolts

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Figure 3: KLS2418ND KLS2430ND KLS2435ND KLS4818ND
KLS4830ND KLS4835ND KLS7218ND KLS7222ND
mounting holes’ dimensions
(dimensions in millimeters)

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Figure 4: KLS2418N KLS2430N KLS4818N KLS4830N KLS7218N KLS7222N
mounting holes’ dimensions
(dimensions in millimeters)

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Figure 5: KLS7230ND KLS7235ND
mounting holes’ dimensions
(dimensions in millimeters)

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Figure 6: KLS7230N
mounting holes’ dimensions
(dimensions in millimeters)

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Figure 7: KLS4860NG KLS7260NG
mounting holes’ dimensions
(dimensions in millimeters) +/B+/B-/U/V/W:M8

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Figure 8: KLS4875NC KLS7275NC KLS48100NC KLS72100NC
KLS48120NC KLS72120NC
mounting holes’ dimensions
(dimensions in millimeters) +/B+/B-/U/V/W:M8

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Figure 9: With Aluminum Liquid Cooling Heatsink at the bottom
Only for 400A and above controllers
mounting holes’ dimensions
(dimensions in millimeters) +/B+/B-/U/V/W:M8

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3.2 Connections
3.2.1 Pin definition of KLS-N Controller
Figure 10:waterproof connector
1，The switch signal is valid to 12V
2，12V only can be used for LED or switch signals.
3，Boost and brake analog regen use the same port on pin2.
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 use two functions at the same time.
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 or can be enabled as High speed switch function. White
(11) 12V:12V Source Red
(25) 12V brake switch. Yellowish
(22) ECO: Low speed switch function. Blue

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(33)CAN-H:Greenish(Optional function)
(7) PWR: Controller power supply (input). Pink
(34)CAN-L:Brownish(Optional function)
DJ7091Y-2.3-21 Pin Definition
(15) Micro_SW: Throttle switch input. Gray
(3) Throttle: Throttle analog input, 0-5V. Dark Green
(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
(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 internally connected.
2. Meter function is to copy either of hall sensors.
3. Switch to 12V is active. Open switch is inactive.
4. F-N-R control and three speed function can not be used at the same time.They both
used the same pin as pin12=FWD
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-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 second braking function of the controller.
Figure 12: Wiring of brake switch(12V): 12V is provided by external source.

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Figure 13: Wiring of brake switch(12V): 12V is provided by KLS-N controller on pin11
Figure 14: Wiring 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 host computer for calibration and
configuration.
Figure 15: RS232 Interface on 4pin connector to RS232 converter
Figure 16：SM-4P connector for communication interface on KLS-N controller

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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.
•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.