Introduction
This manual provides comprehensive instructions for the Kelly KLS7230S and KLS7212S Motor Controllers, designed for high-power 72V motorcycle and scooter applications up to 3000W. These controllers are specifically engineered to integrate with QS brushless hub motors and include a digital TFT speedometer for enhanced functionality. Please read this manual thoroughly before installation and operation to ensure proper use and safety.
Key Features
- Easy connectivity for straightforward installation.
- Compatibility with a wide range of brushless DC motors.
- Adjustable soft start function for smooth acceleration.
- Programmable via Bluetooth for customized settings (optional feature).
- Integrated digital TFT speedometer for real-time data display.
Package Contents
Each set includes the following components:
Combo 1 (KLS7230S)
- 1x Kelly KLS7230S Motor Controller (with customized wiring to match TFT speedometer)
- 1x Digital TFT Color Speedometer Display
Combo 2 (KLS7212S)
- 1x Kelly KLS7212S Motor Controller (with customized wiring to match TFT speedometer)
- 1x Digital TFT Color Speedometer Display
Specifications
KLS7230S Controller
- Type: Sine wave controller, programmable, with regen function
- Motor Current Limit (20 seconds): 300A
- Motor Current Limit (continuous): 120A
- Thermic Probe: KTY83-122
- Dimensions: 140mm x 123mm x 58.5mm
- Net Weight: 1.2kg
- Waterproof Rating: IP54
- Connectivity: USB convertor cable and matched plug included. Bluetooth and CAN BUS not supported by default (Bluetooth is optional).
KLS7212S Controller
- Type: Sine wave controller, programmable, with regen function
- Motor Current Limit (20 seconds): 120A
- Motor Current Limit (continuous): 50A
- Thermic Probe: KTY83-122
- Dimensions: 108mm x 78mm x 41mm
- Net Weight: 0.77kg
- Waterproof Rating: IP54
- Connectivity: USB convertor cable and matched plug included. Bluetooth and CAN BUS not supported by default (Bluetooth is optional).
- Work Voltage: 18V~90V; Rated Voltage: 24V~72V
General Product Information
- Placement on Vehicle: Front
- Country/Region of Manufacture: Mainland China
- Material: Aluminum
- Package Dimensions: Length 29cm, Width 18cm, Height 20cm
- Package Weight: 2.5kg
Setup and Installation
Mounting Dimensions
Refer to the diagram below for the mounting hole dimensions of the KLS7230S controller. Dimensions are in millimeters.
Wiring Diagram and Pin Definitions
Carefully follow the pin definitions and wiring diagrams provided to ensure correct and safe installation. Incorrect wiring can damage the controller or other components.
DJ7091Y-2.3-11 Pin Definitions
- (14) REV_SW: Reverse switch input (Orange wire)
- (6) RTN: Signal return or power supply return (Black wire)
- (12) FWD: Forward switch (White wire)
- (11) 12V: 12V Source (Red wire)
- (9) Relay: Main contactor driver (Blue wire)
- (7) PWR: Controller power supply input (Pink wire)
- (25) 12V: 12V brake switch (Yellowish wire)
DJ7091Y-2.3-21 Pin Definitions
- (15) Micro_SW: Throttle switch input (Gray wire)
- (3) Throttle: Throttle analog input, 0-5V (Green wire)
- (1) Temp: Motor temperature sensor input (Raddle wire)
- (20) RTN: Signal return (Black wire)
- (8) Meter: Copy signal of hall sensors (Dark Gray wire)
- (4) 5V: 5V supply output, <40mA (Purple wire)
- (2) Brake_AN: Brake variable regen or Boost function (Brown wire)
DJ7061Y-2.3-21 Pin Definitions
- (21) RTN: Signal return (Black wire)
- (5) 5V: 5V supply output, <40mA (Purple wire)
- (18) Hall A: Hall phase A (Yellow wire)
- (17) Hall B: Hall phase B (Dark Green wire)
- (16) Hall C: Hall phase C (Dark Blue wire)
Important Notes for Wiring:
- All RTN pins are internally connected.
- The Meter function copies the signal from one of the hall sensors.
- A switch connected to 12V is active; an open switch is inactive.
- If you are unsure about connecting the controller with the motor and other parts, please contact the seller or a qualified technician for assistance.
Operating Instructions
Powering On
The controller can be powered on either by the digital TFT speedometer or by an electric key, depending on your vehicle's setup.
Digital TFT Speedometer
The TFT speedometer displays essential information. It is compatible with various wheel sizes, including 16, 18, 20, 22, 24, 25, 26, 27, 27.5, and 28 inches. The speedometer's logo can be customized for bulk orders (MOQ 5pcs).
Controller Programming and Adjustments
The Kelly controllers feature a clear and user-friendly software interface for adjustments. This allows for customization of various parameters, including the soft start function. Programming can be done via a USB convertor cable, and Bluetooth programming is an optional feature.
Maintenance
To ensure the longevity and optimal performance of your Kelly motor controller and TFT speedometer, consider the following maintenance tips:
- Keep the controller and speedometer clean and free from dust and debris.
- Ensure all connections are secure and free from corrosion.
- Avoid exposing the components to extreme temperatures or direct moisture beyond their IP54 rating.
- Regularly check for any signs of wear or damage to cables and connectors.
Troubleshooting
If you encounter issues with your Kelly motor controller or TFT speedometer, consider the following general troubleshooting steps:
- Verify all wiring connections are correct and secure according to the pin definitions.
- Check the power supply to ensure it is within the specified voltage range for your controller model.
- If the motor is not responding, ensure the throttle is correctly connected and calibrated.
- For programming issues, ensure the USB convertor cable is properly connected and the software is running correctly.
For persistent issues or complex problems, it is recommended to contact the seller's technical support for further assistance.
User Tips
No specific user tips were available from the provided data. Always ensure proper installation and consult the wiring diagrams carefully.
Warranty and Support
For any quality issues where the controller cannot drive the motor upon receipt, a replacement will be provided with your next order for mass purchases. For individual purchases or other support inquiries, please contact the seller directly for assistance. Ensure you provide your product model and a detailed description of the issue.
