Kelly KLS4840D User manual

Kelly KLS-D Brushless Motor Controller User’s Manual V1.5.02
Kelly KLS-D Brushless Motor
Controller User’s Manual
Devices Supported:
Rev.1.5.02
October.2015
KLS4840D
KLS7240D
KLS4850D
KLS7250D
KLS6040D
KLS7275D
KLS6050D

Kelly KLS-D Brushless Motor Controller User’s Manual V1.5.02
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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........................................................................................................................ 7
3.3 Installation Check List......................................................................................................11
Chapter 4 Programmable Parameters................................................................ 12
4.1 Step 1................................................................................................................................. 12
4.2 Step 2................................................................................................................................. 16
4.3 Step 3................................................................................................................................. 17
Chapter 5 Maintenance..........................................................................................18
5.1 Cleaning.............................................................................................................................18
5.2 Configuration.....................................................................................................................19
Table 1: ERROR CODES......................................................................................... 20
Contact Us:..................................................................................................................21

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Chapter 1 Introduction
1.1 Overview
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, 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-D motor
controller must be based on hall sensors type.KLS-D 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.
KLS-D 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 General functions
(1) Extended fault detection and protection. 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) 2 analog 0-5V inputs that default to throttle 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.
(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 or KTY84-150.
(17) 3 hall position sensor inputs. Open collector, pull up provided.
(18) Enhanced regen brake function. A novel ABS technique provides powerful and smooth
regen.The regen can happen at any speeds until zero speed.
(19) KLS-D controller included the fuse and shunt on the case.
(20) Cruise control.
(21) KLS-D can support Broadcast type CAN Bus function.It is 250Kbps.CAN bus is not
included in KLS-D controller by default.
Caution! The regen is not a safe function.Usually you may use the mechanical brake.

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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) Configurable 60 degree or 120 degree hall position sensors.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 with Android 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).

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2.3 Specifications
•Frequency of Operation: 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 50D
KLS:Kelly BLDC motor controller based on sinusoidal waveform which is supposed to
work with BLDC motor with three hall sensors.
72:72V batteries
50:The matched motor is 72V 5KW BLDC motor with hall sensors.
D:The motor Power is＞4KW; S:The motor power ≤4KW
Kelly KLSD Brushless Motor Controller
Model
10 seconds
Current(Amp)
Continuous
Current(Amp)
Voltage(Volt)
KLS4840D
350
140
24-48
KLS4850D
400
160
24-48
KLS6040D
350
140
24-60
KLS6050D
400
160
24-60
KLS7240D
350
140
24-72
KLS7250D
400
160
24-72
KLS7275D
500
200
24-72
1.48V model: range of the batteries is 24V-48V.
2.60V model: range of the batteries is 24V-60V.

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3.72V model: range of the batteries is 24V-72V.
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.
Figure 1:KLSD mounting holes’ dimensions (dimensions in millimeters)

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3.2 Connections
3.2.1 Pin definition of KLS-D Controller
Figure 2: 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
(9) Relay: Main contactor driver. Blue
(33)CAN-H:Green
(7) PWR: Controller power supply (input). Pink

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(34)CAN-L:Dark Gray
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) BOOST: 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-D Controller
Figure 3: KLS-D controller standard wiring
(Battery voltage can be used for controller supply)