Introduction

Overview

• KHS is a sinusoidal motor controller specifically equipped with photo-electric isolation to meet high-voltage (Up to 360V) requirements.
• This manual introduces the features, installation, and maintenance of the Kelly sinusoidal brushless DC (BLDC) motor controller. Please read the manual carefully before using the controller. If you have any questions, contact the Kelly Controls support center.
• Kelly programmable motor controllers provide efficient, smooth, and quiet control for electric motorcycles, golf carts, go-karts, and industrial motor control.
• The primary design focus is to address noise issues in BLDC motor drive applications. The KHS motor controller must be used with Hall sensors and currently does not support sensor-less brushless motors.
• Compared with the traditional trapezoidal control technology, this technology, based on sinusoidal drive technology, can reduce operating noise and switch loss by one-third, meeting the noise reduction and efficiency requirements of brushless DC motor applications. It uses high-power
• MOSFETs, SVPWM, and FOC, achieving up to 99% efficiency in most cases. A powerful microprocessor brings comprehensive and precise control to the controller. It also allows users to quickly and easily adjust parameters, conduct tests, and obtain diagnostic information. The KLS controller can be programmed on both PC software and Android App.
• The KHS features user-friendly I/O terminals, allowing customers to easily connect the battery and motor.

Caution!

• Before running the motor, please start the auto-identification operation first.
• And do not attempt to connect the controller to the user program or change settings in the user program or Android App while the motor is still running.
• In other words, if you want to connect the controller to the user program or attempt to program, please stop the motor first. This is the first step you must take.

Features and Specification

• Model Series: KHS
• Voltage: Up to 360V
• Supported Devices:
  • KHS32020I, KHS36020I, KHS32020IPS, KHS36020IPS, KHS32020IA, KHS36020IA
  • KHS32030N, KHS32035N, KHS32040N, KHS36025N, KHS36030N, KHS36035N

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. The controller will stop driving if the battery voltage is too high. When the battery voltage is low, it will progressively cut back motor drive power as the battery voltage drops. It will also stop driving if the battery voltage reaches the preset “Low Battery Voltage” value.
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. The controller can be programmed and configured using user program or an Android app. For the PC side, please connect the controller and PC using a Kelly USB cable or a USB-RS232 set to use the user program. For the Android side, please connect the controller to a Bluetooth adapter which purchased from out site to use the configuration app on Android devices.
9. Provision of a +5 volt and +12 volt output to supply various kinds of hall sensors and switches.
10. Multiple switches inputs. By default, the switch is effective when the voltage value is 12V.
11. 3 analog inputs (signal is 0-5V), the default are throttle analog input, brake analog input, and motor temperature input.
12. The controller will copy the pulse signal of A-phase Hall sensor for use in the pulse speedometer.
13. Configurable boost function. Enables the maximum motor output if the boost switch is turned on. Regardless of the throttle position, the effect will be the same as full throttle.
14. Configurable joystick throttle. A bi-symmetrical 0-5V signal for both forward and reversing.
15. Configurable motor over-temperature detection and protection with the recommended thermistor KTY84-130/150 or KTY83-122.
16. Only support three-phase hall position sensors. Open collector, pull up provided.
17. At Brake analog regen mode, controller needs another analog input as brake input.
18. Enhanced regen brake function. A novel ABS technique provides powerful and smooth regen. The regen can start at any speeds.
19. Cruise control. Only can be activated in forward direction.
20. Bluetooth supported. Required a Bluetooth adapter which needs to be purchased in addition from our website. This adapter is only useful for KLS controller.
21. User customization on the serial port communication is supported.
22. CAN Bus (Optional), broadcast type, with a customizable baud rate(default at 250Khz) . CAN bus is not included by default in KHS controllers.
23. Bidirectional anti-slip function (Optional), Prevent the stationary vehicle moving in the opposite direction. After the function enabled, when the controller detects that the motor turns from standstill to the opposite direction, it will drive the motor to provide some braking force, making the vehicle stops or slows down. The braking force can be set as required.
24. Electric-magnet brake (Optional).
25. Weak Magnetic Speed Boost Function (Optional).
26. Anti-theft function (Optional), an external alarm is required.
27. Other functions required by the user, require additional customization.
    • Caution! For safety reasons, regen must be used together with mechanical brakes.

Features

1. Smart Control with Powerful Microprocessor.
2. Synchronous rectification, ultra-low voltage drop, fast SVPWM and FOC for very high efficiency.
3. Electronic commutation.
4. Monitoring of 3 motor phases, power bus, and power voltage.
5. Monitoring of 12V and 5V voltage sources.
6. Detection of current in all 3 motor phases.
7. Current control loop.
8. Hardware overcurrent protection.
9. Hardware overvoltage protection.
10. Configurable motor current and battery current limits.
11. Low EMC.
12. Battery protection: current reduction, warning, and shutdown at configured high and low voltage levels.
13. The PCB is mounted on an aluminum base plate with a heat sink on the bottom of the controller.
14. Various connector sets which supporting small signals, with waterproof connector set by default.
15. Thermal protection: current reduction, warning, and shutdown at high temperatures.
16. Automatic identification feature for Hall sensors mounted at any angle.
17. Configurable high pedal protection: if high throttle is detected at startup, the controller will not operate.
18. Current multiplication: drawing less current from the battery while outputting more current to the motor.
19. Easy installation: Operates with Just a 3-Wire Potentiometer.
20. Programming via standard PC/laptop,user program provided. Easy to use. No cost to customers.
21. Supports motors with any number of poles.
22. Standard electrical speed up to 70,000 eRPM (electrical speed = mechanical speed * number of pole pairs; number of pole pairs = number of poles / 2).
23. Dust-proof and waterproof under sealed conditions, IP66.

Specifications

1. Frequency of Operation: 10KHz, 16KHz, 20KHz.
2. Standby Battery Current: < 0.5mA.
3. 5V or 12V Sensor Supply Current: 40mA.
4. Supply(PWR) Current: 30mA Typical.
5. Battery voltage(B+) range: Configurable.
6. Standard Throttle Input: 0-5V(3-wire resistive pot), 1-4V(hall active throttle).
7. Full Power Operating Temperature Range: 0℃ to 70℃(MOSFET temperature).
8. Operating Temperature Range: -40℃to 100℃ (MOSFET temperature).
9. Max Battery Current: Configurable.
10. Max Motor Current: Configurable.

Name Regulation

The name regulation of Kelly BLDC motor controllers:

• For example: KHS32020I/KHS32030NPS
• KHS: Kelly optical-isolated BLDC motor controller based on sinusoidal waveform which is suitable for operation under high voltage. KHS controllers can do regen brake function by default.
• 320: 320V battery pack.
• I: Standard housing, smaller and lighter than N model, compatible with Hall sensors. Liquid cooled by default.
• N: Sealed aluminum housing，Enhanced cooling performance，compatible with Hall sensors. Liquid cooled by default.
• IPS: Standard housing, smaller and lighter than N model, compatible with Sin/Cosine sensors. Liquid cooled by default.
• NPS: Sealed aluminum housing，Enhanced cooling performance，compatible with Sin/Cosine sensors. Liquid cooled by default.
• IA: Standard housing, smaller and lighter than N model, compatible with ABZ Encoders. Liquid cooled by default.
• NA: Sealed aluminum housing，Enhanced cooling performance，compatible with ABZ Encoders sensors. Liquid cooled by default.

Wiring and Installation

Mounting the Controller

• The controller can be placed anywhere but should be kept as clean and dry as possible.
• If necessary, covering with a cover to prevent water and contaminants from entering.
• To ensure full rated output power, the controller should be mounted on a clean, flat metal surface and secured with screws on all four mounting holes. Apply silicone grease or other thermally conductive material to the contact surfaces to 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.

Connections
Pin definition of KHS Controller

DJ7091Y-2.3-11 Pin Definition

1. REV_SW(14): Reverse switch input. ※Orange
2. GND(6): Signal return or power supply return. ※Black
3. FWD(12): Forward switch or can be enabled as High speed switch function. ※
   White
4. 12V(11): 12V Supply. ※Red
5. 12V (25): brake switch. ※Yellowish
6. ECO(22): Low speed switch. ※Blue
7. CAN-H(33): (Optional function). ※Greenish
8. PWR(7): Controller power supply (input). ※Pink
9. CAN-L(34): (Optional function). ※Brownish

DJ7091Y-2.3-21 Pin Definition

1. Foot_SW(15): Throttle switch input. ※Gray
2. Throttle(3): Throttle analog input, 0-5V. ※ Green
3. GND(20): Signal return. ※Black
4. Meter(8): Copied signal of hall-A sensor. ※Dark Gray
5. 5V(4): 5V Supply, <40mA. ※Purple
6. Brake_AN(2): Brake variable regen or Boost function. ※Brown
7. 12V(11): 12V Supply. ※Red

DJ7061Y-2.3-21 Pin Definition

1. GND(21): Signal return. ※Black
2. Temp(1): Motor temperature sensor input. ※Raddle.
3. 5V(5): 5V Supply, <40mA. ※Purple
4. Hall A(18): Hall sensor signal of phase-A. ※Yellow (Also used as Sine signal input on KHS-NPS)
5. Hall B(17): Hall sensor signal of phase-B. ※Dark Green (Also used as Cosine signal input on KHS-NPS)
6. Hall C(16): Hall sensor signal of phase-C. ※Dark Blue (This port is reserved on KHS-NPS)

35pin connector definition

776164 Pin Definition

Source of Value *:

1. User: Users should modify these values to adjust the controller.
2. Auto: These values are generated by the sensor or the controller’s program, and users can affect the operation of the controller by modifying these values.
3. Default: These values are factory presets or sensor readings, cannot be modified by the user program.

Maintenance

Caution! There are no user-serviceable parts inside the controller. Do not attempt to open the controller on your own, as this will void your warranty. The exterior of the controller should be cleaned periodically. The controller is a high powered device. When working with any battery powered vehicle, proper safety precautions should be taken that include, but are not limited to propertraining, wearing eye protection, avoidance of loose clothing, hair and jewelry, using insulated tools.

Although the controller virtually requires no maintenance after proper installation, it is recommended to follow these steps during use:

1. Disconnect the battery, starting with the positive terminal, to cut off the power.
2. Discharge the capacitors in the controller by connecting a load (such as a contactor coil, resistor, or horn) across the controller’s B+ and B- terminals.
3. Regularly remove any dirt or corrosion from the bus bar area. Wipe the controller with a moist rag and ensure it is completely dry before reconnecting the battery.
4. Make sure the connections to the bus bars are tight. To avoid physically stressing the bus bars, use two well-insulated wrenches for the operation.
5. Fanned model require routine fan maintenance, including ensuring the fan rotate normally and cleaning the dust on the fan.

Table 1: Error Codes

External LED Error Codes
To display the error code, please install an external LED indicator first.

Devices Supported:

Contact Us

• Kelly Controls
• Home Page: http://www.KellyController.com
• Download user manual, instructions and user program: https://kellycontroller.com/support/
• E-mail: Sales@Kelly-Controls.com
• Phone: (01) 224 637 5092

FAQs

• Q: Can the KHS motor controller be used with sensor-less brushless motors?
  • A: No, the KHS motor controller must be used with Hall sensors and does not support sensor-less brushless motors.
• Q: What should I do before running the motor with the controller?
  • A: Start the auto-identification operation first before running the motor. Do not attempt to connect to the user program or change settings while the motor is running.