Kelly KLS4860NE User manual

Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9
Kelly High-current series KLS-N
Sinusoidal Brushless Permanent Magnet Motor Controllers
User’s Manual
Devices Supported:
KLS4860NG
KLS7260NG
KLS4860NE
KLS7260NE
KLS4875NC
KLS7275NC
KLS48100NC
KLS72100NC
KLS48120NC
KLS72120NC
Rev. 2.9

Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9
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 ......................................................................................................9
3.3 Installation Check List....................................................................................13
Chapter 4 Programmable Parameters.......................................................................14
4.1 Step 1 ..............................................................................................................14
4.2 Step 2 ..............................................................................................................19
4.3 Step 3 ..............................................................................................................20
4.4 How to use Identification angle operation function.......................................22
Chapter 5 Maintenance.............................................................................................27
5.1 Cleaning..........................................................................................................27
5.2 Configuration..................................................................................................27
Table 1: Error Codes....................................................................................................28
Contact Us:..................................................................................................................30

Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9
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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 novelABS 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
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

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

Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9
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Figure 8: KLS4875NC KLS7275NC KLS48100NC KLS72100NC
KLS48120NC KLS72120NC
mounting holes’ dimensions
(dimensions in millimeters) +/B+/B-/U/V/W:M8

Kelly KLS-N Sinusoidal Brushless Permanent Magnet Motor Controller User’s Manual V2.9
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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

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(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
(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.

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Figure 12: Wiring of brake switch(12V): 12V is provided by external source.
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

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Figure 16：SM-4P connector for communication interface on KLS-N 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.
•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

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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 orAndroid 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 20~86, depending on model.
Controller will not operate when battery voltage is near the value so as to protect battery.
Suggestion: Set according to the practical situation.
(2)Over Volt: The max voltage of reporting this fault - Range 20~86, depending on model.
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 86V for 72V controller.
Controller Rated voltage
Under Voltage Range (V)
Over Voltage Range(V)
24V
20~30
20~30
60V
40~80
40~80

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72V
40~86
40~86
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%.
(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

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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
(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%
Midspeed Forw speed, Midspeed Rev speed, Lowspeed Forw speed and Lowspeed Rev speed.

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Range: 20~100 By default, it is set at 100%.Both F-N-R control and three speed function used
the same pin12.Needless to say, we can not use both functions at the same time. Three Gears
switch is supposed to enable F-N-R control. When this item is disabled, we can use three speed
function, vice versa.
Pin22 is low speed switch input port while Pin12 is high speed switch input port. When both
pin22 and pin12 are disconnected from pin11,the controller is driving with medium speed mode.
Three speed: This item is used to enable or disable three speed function. By default, it is at 0
0:Three speed function is disabled.1:Two speed function.2:Three speed function is enabled.
(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.
If throttle got effective output, the controller will report fault and not operate.
Suggestion: Set according to the practical situation, factory default is Enable.
(20)Brake H-Pedal: Releasing Brake High Pedal Disable
Value range: Enable and Disable
Functional description: If enabled, the controller will detect the current pedal status when
release the brake. If throttle got effective output, the controller will report fault and not operate.
Suggestion: Set according to the practical situation, factory default is Disable.
(21)NTL H-Pedal: Neutral position High Pedal Disable. 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 output signal, the controller will not operate and report fault code.
Suggestion: Set according to the practical situation, factory default is Disable.
(22)Joystick function:
If enable, the controller can drive the motor on two directions without using any reversing
switch.
Just one single throttle can drive the motor on forward and reversing direction.
The stick shift throttle firmware can be called wig-wag or joystick operation. It is only a software
function. Usually It is useful for electric boat project. You still can use the common 0-5K pot or
0-5V throttle for the controller. If you don't choose the joystick, you operated the throttle in this

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way. The motor speed will increase when the throttle is from 0V to 5V.
If you enable joystick for this controller in user program, you will start the motor from 2.5V
position.2.6V to 5V is forward.2.4V to 0V is backward.
2.4V to 2.6V is the throttle dead zone. Customers can adjust the throttle dead zone in user
program also.
Please note the common throttle will spring back to original position if you release the throttle.
Suggestion: factory default is Disable.
(23)Three Gears switch: It is used for function of F-N-R control.
Please check the wiring diagram in the manual for F-N-R control.
Suggestion: Set according to the practical situation, factory default is Disable.
(20-A)Three Gears Switch
Value range: Enable and Disable
Functional description: If enabled, the Forward switch will be activated. Please see figure 4.1.
Suggestion: Set according to the practical situation, factory default is Disable.
(20-B)Foot Switch
Value range: Enable and Disable
Functional description: If enabled, the foot switch will be activated. The controller will not accept
the throttle signal if the foot switch is turned off. Please see figure 4.1.
Suggestion: Set according to the practical situation, factory default is Disable.
Configuration
Pin Status
Running
Status
Forward
Switch
Foot Switch
FWD_SW
(12)
REV_SW
(14)
Foot
(15)
Enable
Disable
OFF
OFF
x
Neutral
OFF
ON
x
Reverse
ON
OFF
x
Forward
ON
ON
x
Neutral
Disable
Enable
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 controller will output max power for a while.
Boost function is just full throttle position when you turn on boost switch even if the throttle is not
operated at all.