Kelly KLS-N Series High Current Sinusoidal BLDC Motor Controllers
Introduction
Overview
KLS-N HC is a variant of the standard KLS-N model, offering significant performance improvements in a larger size, while still maintaining the same IP66 protection. 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 KLS-N motor controller must be used with Hall sensors and currently does not support sensorless 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 apps. The KLS-N 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. 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 programming, please stop the motor first. This is the most important thing.
Features and Specifications
General Functions
- Extended fault detection and protection. Customers can read the error message in PC software or Android APP also.
- 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. - Built-in current loop and over-current protection.
- Configurable motor temperature protection range.
- 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℃.
- The controller keeps monitoring the battery recharging voltage during regen braking.
- Maximum reverse speed and forward speed can be configured between 20% and 100% respectively and separately.
- The controller can be programmed and configured using a 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 purchased from our site to use the configuration app on Android devices.
- Provision of a +5 volt and +12 volt output to supply various kinds of hall sensors and switches.
- Multiple switch inputs. By default, the switch is effective when the voltage value is 12V.
- 3 analog inputs (signal is 0-5V), the default is throttle analog input, brake analog input, and motor temperature input.
- The controller will copy the pulse signal of the -phase Hall sensor for use in the pulse speedometer.
- 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 a full throttle.
- Configurable joystick throttle. A bi-symmetrical 0-5V signal for both forward and reversing.
- Configurable motor over-temperature detection and protection with the recommended thermistor KTY84-130/150 or KTY83-122.
- Only support three-phase hall position sensors. Open collector, pull-up provided.
- At the Brake analog regen mode, the controller needs another analog input as brake input.
- Enhanced regen brake function. A novel ABS technique provides powerful and smooth regen. The regen can start at any speed.
- Cruise control. Only can be activated in the forward direction.
- Bluetooth supported. Required a Bluetooth adapter which needs to be purchased in addition from our website. This adapter is only useful for the KLS controller.
- User customization on the serial port communication is supported.
- CAN Bus (Optional), broadcast type, with a customizable baud rate(default at 250Khz). CAN bus is not included by default in KLS-N controllers.
- Bidirectional anti-slip function (Optional), Prevent the stationary vehicle from moving in the opposite direction. After the function is enabled when the controller detects that the motor turns from a standstill to the opposite direction, it will drive the motor to provide some braking force, making the vehicle stop or slowdown The braking force can be set as required.
- Pedal Assist System (Optional), assisting the rider when they pedal.
- Electric-magnet brake (Optional).
- Weak Magnetic Speed Boost Function (Optional).
- Anti-theft function (Optional), an external alarm is required.
- Built-in DC/DC Module (Optional), to supply external peripherals. (13.5V,2A)
- Other functions required by the user, require additional customization.
Caution: For safety reasons, regen must be used together with mechanical brakes.
Features
- Smart Control with Powerful Microprocessor.
- Synchronous rectification, ultra-low voltage drop, fast SVPW, M, and FOC for very high efficiency.
- Electronic commutation.
- Monitoring of 3 motor phases, power bus, and power voltage.
- Monitoring of 12V and 5V voltage sources.
- Detection of current in all 3 motor phases.
- Current control loop.
- Hardware overcurrent protection.
- Hardware overvoltage protection.
- Configurable motor current and battery current limits.
- Low EMC.
- Battery protection: current reduction, warning, and shutdown at configured high and low voltage levels.
- The PCB is mounted on an aluminum base plate with a heat sink on the bottom of the controller.
- Various connector sets support small signals, with waterproof connector set by default.
- Thermal protection: current reduction, warning, and shutdown at high temperatures.
- Automatic identification feature for Hall sensors mounted at any angle.
- Configurable high pedal protection: if a high throttle is detected at startup, the controller will not operate.
- Current multiplication: drawing less current from the battery while outputting more current to the motor.
- Easy installation: Operates with Just a 3-Wire Potentiometer.
- Programming via standard PC/laptop, user program provided. Easy to use. No cost to customers.
- Supports motors with any number of poles.
- Standard electrical speed up to 70,000 eRPM (electrical speed = mechanical speed * number of pole pairs; number of pole pairs = number of poles / 2).
- Dust-proof and waterproof under sealed conditions, IP66.
Specifications
- Frequency of Operation: 10KHz, 16KHz, 20KHz.
- Standby Battery Current: < 0.5mA.
- 5V or 12V Sensor Supply Current: 40mA.
- Supply(PWR) Current: 30mA Typical.
- Battery voltage(B+) range: Configurable.
- Standard Throttle Input: 0-5V(3-wire resistive pot), 1-4V(hall active throttle).
- Full Power Operating Temperature Range: 0℃ to 70℃(MOSFET temperature).
- Operating Temperature Range: -40℃to 100℃ (MOSFET temperature).
- Max Battery Current: Configurable.
- Max Motor Current: Configurable.
Name Regulation
The name regulation of Kelly BLDC motor controllers: For example KLS7275NT
- 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 the regen brake function by default.
- 72: 72V battery pack.
- N: Large housing, providing better current performance.
- NT: Compact large housing, smaller and lighter compared to the N model. It has standard current performance.
Wiring and Installation
Mounting the Controller
The controller can be placed anywhere but should be kept as clean and dry as possible. If necessary, cover 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.
KLS4860NT KLS7275NT mounting holes’ dimensions (dimensions in millimeters) +/B+/B-/U/V/W: M8
KLS4875N KLS48100N KLS48120N KLS7275N KLS72100N KLS72120N KLS72150N KLS8475N KLS84100N KLS84120N KLS84150N mounting holes’ dimensions (dimensions in millimeters) +/B+/B-/U/V/W:M8
Within Aluminum Liquid Cooling Heatsink at the bottom mounting holes’ dimensions (dimensions in millimeters) +/B+/B-/U/V/W: M8
Connections
DJ7091Y-2.3-11 Pin Definition
- REV_SW(14): Reverse switch input. ※Orange
- GND(6): Signal return or power supply return. ※Black
- FWD(12): Forward switch or can be enabled as a High-speed switch function. ※ White
- 12V(11): 12V Supply. ※Red
- 12V (25): brake switch. ※Yellowish
- ECO(22): Low-speed switch. ※Blue
- CAN-H(33): (Optional function). ※Greenish
- PWR(7): Controller power supply (input). ※Pink
- CAN-L(34): (Optional function). ※Brownish
DJ7091Y-2.3-21 Pin Definition
- Foot_SW(15): Throttle switch input. ※Gray
- Throttle(3): Throttle analog input, 0-5V. ※ Green
- GND(20): Signal return. ※Black
- Meter(8): Copied signal of hall-A sensor. ※Dark Gray
- 5V(4): 5V Supply, <40mA. ※Purple
- Brake_AN(2): Brake variable regen or Boost function. ※Brown
- 12V(11): 12V Supply. ※Red
DJ7061Y-2.3-21 Pin Definition
- GND(21): Signal return. ※Black
- Temp(1): Motor temperature sensor input. ※Raddle.
- 5V(5): 5V Supply, <40mA. ※Purple
- Hall A(18): Hall sensor signal of phase-A. ※Yellow
- Hall B(17): Hall sensor signal of phase B. ※Dark Green
- Hall C(16): Hall sensor signal of phase C. ※Dark Blue
Notes
- All GND pins are internally connected.
- The meter function is to output the signal of the hall-A sensor.
- Three gears and three speeds function can’t be used at the same time by default. Because FWD in three gears and High-speed in three speeds use the same pin (FWD, Pin12).
- The switch signal is valid at 12V.
- 12V output（Pin11）can only be used for switch signals, with a total current not exceeding 40mA.
- CAN bus is not included in the KLS-N controller by default.
- Boost and brake analog regen use the same port on Brake_AN(Pin2). When boost is disabled in a user program, Pin2 is used for brake analog regen. When boost is enabled, Pin2 is used for the cost function. Due to port conflicts, these two functions can’t operate simultaneously on the same port.
KLS-N Controller Standard Wiring
The battery is also used as the controller’s power supply.
Caution: Make sure the controller wiring is correct and has been double-checked, especially the B+ and the B- of the controller before powering on. 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. Contactors in the B+ line must have a diode across their coils. It was used as a freewheel diode. Lacking this diode may cause serious damage to the power module. Please install this diode as KLS-N controller standard wiring shown above.
Communication Port
A 4-pin connector is provided to communicate with the host for calibration and configuration.
Installation Check List
- Conduct a visual inspection to ensure that components such as mounting holes, wiring, and sealing rings are intact.
- Check the connection between the battery B+ and NC. For controllers without a fuse, check the connection between the battery B+ and the controller B+ instead of NC.
- Check the connection between the battery B- and the controller B-.
- Verify the connections of all signal wires and ensure that their PWR and GND are properly isolated from each other.
- Check the connection of the motor’s Hall wires, the 5V and GND wires should correspond with the motor’s interface.
- Verify the connection of the throttle wires, the 5V and GND wires should correspond with the throttle’s interface.
- Check the connection of the gear wires. It is valid at 12V by default.
Configuration Program
KLS Configuration program allows users to adjust various parameters according to their needs, enabling the motor to achieve optimal performance. The default parameters may not be suitable for all situations. Please ensure that all parameters are adjusted to appropriate values before testing to avoid any potential dangers. Customers can program using either a PC program or an Android app. Before operating the motor, an automatic identification process must be performed. During the process, the controller needs to be connected to the batteries, motor, and throttle. And the PWR(Pin7) needs to be connected with battery B+ to power the controller. Please perform the automatic identification process according to the automatic identification guide.
Notes
- When configuring existing parameters in the user program or Android app, disconnect the controller from the motor or at least stop the motor.
- The controller may display fault codes when adjusting parameters, but it will not affect programming or configuration. However, it will affect the auto-identification operation, so please try to eliminate error codes before performing the auto-identification operation.
- Use the RS232-USB cable and SM-4P adapter provided by Kelly to connect to a host computer. During the operation the PWR of the controller needs to be provided with >+18V (for a 24V controller, provide >+8V). Connect the GND to battery B-.
- To connect to Android devices, the LS controller requires a Bluetooth adapter.
Connecting to upper host
You have three ways to connect the controller to host computers or Android devices:
- Using the Kelly USB cable, connect SM-4P (Female) from the controller to the USB port on the computer. You may download the Kelly USB Cable driver or at our website. (https://media.kellycontroller.com/new/CH341SER.zip)
- Using the RS232-USB cable along with the SM-4Pin adapter, connect SM-4Pin (Female) from the controller to the USB port on the computer. You may download the USB-RS232 driver at our website. (https://media.kellycontroller.com/new/USB-CONVERTER-RS232-Win10.zip)
- Using Bluetooth adapter. Connect it to SM-4P (Female) then connect the controller to Android devices through Bluetooth. This Bluetooth adapter can be purchased from our website.(https://kellycontroller.com/shop/usb-adapter)
How to use auto-identification
Here is a brief overview of the automatic identification process:
- Connect the controller and the motor according to the standard wiring diagram. Please make sure there is no load on the motor shaft before starting the programming.
- Connect the controller to the PC by using a Kelly USB cable or a USB to RS232 set. For Android devices, please use the Bluetooth adapter to connect the controller.
- Download the corresponding USB drivers and the user program from our website, only one driver can be installed, two drivers installed at the same time are incompatible. After the USB driver is successfully installed, please restart your PC.
- Turn the key switch to supply power to the controller from B+/B- and PIN7, then open the user program on your device. Click the ‘READ’ button to open the initial interface as the figure below.
Please check whether the value of Identification_Angle is at 85. The 85 means this controller had finished the automatic identification operation with the motor in the factory before. It is still needed to run an automatic identification operation before running. - Fill 170 in the Identification_Angle value. Then click the write button. The user program will give a pop-up window that shows the Write operation has succeeded. Then exit from the user program and turn off the power supply.
- Turn on the power supply after the power supply is off for a few seconds. The motor shaft will try to run in random directions. This is a normal operating phenomenon.
- Wait about 2-3 minutes. The beeper will beep as error code 3-2, meaning the automatic identification operation is finished normally. You will see a reset error message on the monitor screen of the user program.
- Turn off the power supply again. Then wait about a few seconds to turn on the power supply again.
- Connect the controller to the user program. You will see 85 in the Identification_Angle. This means, that the controller auto-identification operation has succeeded. The motor is ready to run.
- If the Identification_Angle value is 170, it means that auto-identification is still in progress.
- If no error code is triggered, please do not manually write 85 to Identification_Angle or restart the power supply.
- If a constant beep sound lasts above 5 minutes and there are other error codes such as Identify error, hall error, etc, please return to the initial interface of the user program and write 85 to Identification_Angle manually.
- Before turning off the power supply, make sure that Identification_Angle is not at 170. Otherwisee the controller will try to keep doing identificatiooperationson all the time after you turn the on power supply again. When the error codes occur, please quit from user program and try step 6 again.
- After successful identification, make sure that Identification_Angle is not at 170. Then you may turn on the power supply.
- If the direction of the motor is not what you expected, there is no need for you to cooperate again, just check the Change Direction option in the last part of the initial interface then click the Write button and reset, and the motor will run in the opposite direction.
Program parameters and value
On the program’s initial interface, these items are listed:
Source of Value
- User: Users should modify these values to adjust the controller.
- 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.
- Default: These values are factory presets or sensor readings that 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 proper training, wearing eye protection, avoidance of loose clothing, hair, and jewelry, and iusinginsulated tools.
Although the controller virtually requires no maintenance after proper installation, it is recommended to follow these steps during use:
- Disconnect the battery, starting with the positive terminal, to cut off the power.
- 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.
- 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.
- 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.
- Fanned models require routine fan maintenance, including ensuring the fan rotates normally and cleaning the dust on the fan.
Error Codes
Buzzer Error Codes
Contact Us
Home Page: http://www.KellyController.com
DDownload the 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 KLS-N motor controller be used with sensorless brushless motors?
A: No, the KLS-N motor controller must be used with Hall sensors and currently does not support sensorless brushless motors.
Q: What caution should be taken before running the motor with the controller?
A: Before running the motor, start the auto-identification operation first. Do not attempt to connect the controller to the user program or change settings while the motor is running.
Documents / Resources
 | Kelly KLS-N Series High Current Sinusoidal BLDC Motor Controllers [pdf] User Manual KLS-N Series High Current Sinusoidal BLDC Motor Controllers, KLS-N Series, High Current Sinusoidal BLDC Motor Controllers, Sinusoidal BLDC Motor Controllers, BLDC Motor Controllers, Motor Controllers, Controllers |
