KLS-N Series High Current Sinusoidal BLDC Motor Controllers
“
Specifications:
- Model: Kelly High-current KLS-N series
- Devices Supported:
- KLS4875N
- KLS48100N
- KLS48120N
- KLS7275NT
- KLS7275N
- KLSAA72100N KLS72120N
- KLS72150N
- KLS8475N
- KLS84100N
- KLS84120N
- IP Rating: IP66
Product Usage Instructions:
Chapter 1: Introduction
1.1 Overview
The KLS-N HC is an upgraded version of the standard KLS-N model,
offering improved performance while maintaining an IP66 protection
rating. It is designed for electric motorcycles, golf carts,
go-karts, and industrial motor control applications. This manual
provides information on features, installation, and maintenance
procedures.
Chapter 2: Features and Specification
2.1 General functions
The controller delivers efficient, smooth, and quiet performance
for various applications.
2.2 Features
– Specifically designed to address noise issues in BLDC motor
drive systems.
– Must be used with Hall sensors.
– Does not support sensorless brushless motors.
2.3 Specifications
– Can be programmed using PC software or Android app.
– User-friendly I/O terminals for easy connection of battery and
motor.
2.4 Name Regulation
Chapter 3: Wiring and Installation
3.1 Mounting the Controller
Follow the mounting instructions provided in the manual to
ensure proper installation.
3.2 Connections
Refer to the manual for detailed instructions on connecting the
controller to the battery and motor.
3.3 Installation Check List
Before operation, review the installation checklist to verify
all connections and settings.
Chapter 4: Configuration Program
Details about programming the controller using PC software or
the Android app can be found in this section of the manual.
Chapter 5: Maintenance
Instructions on maintenance procedures to keep the controller in
optimal condition are outlined in this chapter.
FAQ:
Q: Can the KLS controller be used with sensorless brushless
motors?
A: No, the KLS controller must be used with Hall sensors and
does not support sensorless brushless motors.
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Kelly High-current series Sinusoidal BLDC Motor Controller User Manual
V2.1.2
Kelly High-current KLS-N series
High-current Sinusoidal BLDC Motor Controllers
User Manual
KLS4860NT
Devices Supported:
KLS4875N
KLS48100N
KLS48120N
KLS7275NT
KLS7275N
KLSAA72100N KLS72120N
KLS72150N
KLS8475N
KLS84100N
KLS84120N
Rev. 2.1.2 Aug. 2025
Kelly High-current series Sinusoidal BLDC Motor Controller User Manual
V2.1.2
Contents
Chapter 1 Introduction…………………………………………………………………………. 2
1.1 Overview…………………………………………………………………………………………………. 2
Chapter 2 Features and Specification ……………………………………………………. 3
2.1 General functions …………………………………………………………………………………….. 3 2.2 Features …………………………………………………………………………………………………. 5 2.3 Specifications ………………………………………………………………………………………….. 6 2.4 Name Regulation……………………………………………………………………………………… 6
Chapter 3 Wiring and Installation ………………………………………………………….. 7
3.1 Mounting the Controller …………………………………………………………………………….. 7 3.2 Connections…………………………………………………………………………………………… 12 3.3 Installation Check List …………………………………………………………………………. 15
Chapter 4 Configuration Program ……………………………………………………….. 16
Notes …………………………………………………………………………………………………………. 16 4.1 Connecting to upper host…………………………………………………………………….. 18 You have three ways to connect the controller to host computers or Android devices: …………………………………………………………………………………………………………………. 18 4.3 Program parameters and value ……………………………………………………………. 21
Chapter 5 Maintenance……………………………………………………………………… 28
Table 1: Error Codes …………………………………………………………………………… 29
Contact Us:………………………………………………………………………………………….. 30
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Chapter 1 Introduction
1.1 Overview
The KLS-N HC is an upgraded version of the standard KLS-N model, providing significantly improved performance and a larger body, while still retaining the same IP66 protection rating. This manual provides an overview of the features, installation, and maintenance procedures for the Kelly sinusoidal brushless DC (BLDC) motor controller. Please read this manual carefully before using the controller. If you have any questions, contact the Kelly Controls Support Center.
Kelly programmable motor controllers deliver efficient, smooth, and quiet performance for electric motorcycles, golf carts, go-karts, and industrial motor control applications.
The KLS-N series is specifically designed to address noise issues in BLDC motor drive systems. This controller must be used with Hall sensors and does not currently support sensorless brushless motors.
Compared with traditional trapezoidal control methods, the sinusoidal drive technology employed by the KLS-N reduces operating noise and switching losses by up to one-third, meeting stringent noise reduction and efficiency requirements for BLDC motor applications. Utilizing high-power MOSFETs, SVPWM, and FOC, the controller achieves efficiency levels of up to 99% in most scenarios. A powerful microprocessor provides comprehensive and precise control while enabling users to quickly adjust parameters, run diagnostics, and conduct testing.
The KLS controller can be programmed using either PC software or the Android app. User-friendly I/O terminals make it easy to connect the battery and motor.
Caution! Before running the motor, perform the auto-identification procedure. Do not attempt to connect the controller to the user program or change any settings in the PC software or Android app while the motor is running. In other words, always stop the motor before connecting to the user program or attempting to adjust parameters. This is a mandatory safety step.
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Chapter 2 Features and Specification
2.1 General functions
1. Extended fault detection and protection functions. Customers can view error information via PC software or Android application.
2. Constant monitoring of battery voltage. If the battery voltage is too high, the controller will stop driving. When the battery voltage is too low, the controller will gradually reduce the motor drive power as the battery voltage drops. The controller will also stop driving when the battery voltage reaches the preset “low battery voltage” threshold.
3. Built-in current loop and over current protection. 4. Configurable motor temperature protection range. 5. Low and high temperature current reduction function to protect the battery and controller. The current
begins to decrease when the case temperature reaches 90°C and shuts down completely at 100°C. 6. During regenerative braking, the controller continuously monitors the battery charge voltage. 7. The maximum reverse speed and forward speed can be configured between 20% and 100%
respectively. 8. The controller can be programmed and configured using the user program or Android app. For PC,
please use Kelly USB cable or USB-RS232 converter to connect the controller and PC, and then you can use the user program. For Android, please use the Bluetooth Adapter purchased from us to connect the controller, and then use the configuration app on your Android device. 9. +5 V and +12 V outputs are provided to power various Hall sensors and switches. 10. Multiple switch inputs. By default, the switch input is valid when it is 12 V. 11. 3 analog inputs (signal range is 0-5 V), which are throttle analog input, brake analog input and motor temperature input by default. 12. The controller replicates the A-phase Hall sensor pulse signal for the pulse speedometer. 13. Configurable boost function. When the boost switch is turned on, the motor will get the maximum output power. Regardless of the throttle position, the effect is the same as full throttle. 14. Configurable joystick throttle. Both forward and reverse directions support dual symmetrical 05 V signals. 15. Configurable motor over-temperature detection and protection, recommended thermistor KTY84-130/150 or KTY83-122. 16. Only supports three-phase Hall position sensors. Open collector and pull-up resistors are provided. 17. In brake analog regeneration mode, the controller requires another analog input as brake input. 18. Enhanced regenerative braking function. Innovative ABS technology provides strong and smooth regeneration. Regeneration function can be activated at any speed. 19. Cruise control. Can only be activated when driving in forward direction. 20. Support Bluetooth. Bluetooth Adapter is required and needs to be purchased separately from our website. This adapter is only suitable for KLS controllers. 21. Support user-defined serial port communication. 22. CAN bus (optional), broadcast type, baud rate can be customized (default 250Khz). KLS-N controller does not include CAN bus by default.
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23. Bidirectional anti-slip function (Optional), prevent the stationary vehicle from moving in the opposite direction. When this function is enabled, the controller detects if the motor starts turning in the opposite direction from a stationary state and applies braking force to stop or slow down the vehicle.The braking force can be set as needed.
24. Pedal assist system (optional) to provide assistance when the rider pedals. 25. Electromagnetic brake (optional). 26. Field weakening function (optional), to increase the max speed. 27. Anti-theft function (optional), requires an external alarm. 28. Built-in DC/DC module(Optional), to power external devices (13.5 V, 2A) 29. Other user-defined customizable functions.
Caution! For safety reasons, regen must be used together with mechanical brakes.
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2.2 Features
1. Intelligent control powered by a high-performance microprocessor. 2. Synchronous rectification, ultra-low voltage drop, fast SVPWM, and FOC for maximum
efficiency. 3. Electronic commutation. 4. Monitoring of motor three phases, power bus, and supply voltage. 5. Monitoring of 12 V and 5 V voltage sources. 6. Detection of current in all three motor phases. 7. Current control loop for precise motor control. 8. Hardware overcurrent protection. 9. Hardware overvoltage protection. 10. Configurable limits for motor current and battery current. 11. Low EMC. 12. Battery protection with configurable current reduction, warnings, and shutdown at high or
low voltage levels. 13. PCB mounted on an aluminum base plate with a heatsink integrated into the bottom of
the controller. 14. Various connector sets supporting small signals; waterproof connector set provided by
default. 15. Thermal protection: automatic current reduction, warnings, and shutdown at high
temperatures. 16. Automatic identification of Hall sensors mounted at any angle. 17. Configurable high-throttle protection: prevents operation if a high throttle signal is
detected at startup. 18. Current multiplication: draws less current from the battery while delivering higher current
to the motor. 19. Easy installation: operates with only a 3-wire potentiometer. 20. Programming via standard PC or laptop; user program provided free of charge and easy
to use. 21. Supports motors with any number of poles. 22. Supports electrical speeds up to 70,000 eRPM (electrical speed = mechanical speed ×
number of pole pairs; pole pairs = number of poles ÷ 2). 23. Dustproof and waterproof under sealed conditions (IP66 rating).
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2.3 Specifications
1. Frequency of operation: 10kHz, 16kHz, 20kHz (selectable). 2. Standby battery current: <0.5mA. 3. 5V or 12V sensor supply current: 40mA max. 4. Supply (PWR) current: 30mA (typical). 5. Battery voltage (B+) range: configurable. 6. Standard throttle input: 05V (3-wire resistive potentiometer) or 14V (active Hall
throttle). 7. Full-power operating temperature range: 0°C to 70°C (MOSFET temperature). 8. Operating temperature range: -40°C to 100°C (MOSFET temperature). 9. Maximum battery current: configurable. 10. Maximum motor current: configurable.
2.4 Name Regulation
The name regulation of Kelly BLDC motor controllers:
For example: KLS7275NT.
KLS: Kelly BLDC motor controller based on sinusoidal waveform. Designed to work with
BLDC motors equipped with three Hall sensors. All KLS controllers support regenerative braking by default.
72: 72V battery pack.
N: Denotes a large housing, which allows for better current handling performance.
NT: Refers to a compact version of the large housing (“N”), offering a smaller and lighter
design while providing standard current performance.
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Kelly KLS-N – Sinusoidal Brushless Permanent Magnet Motor Controller
Model
Nominal
Max Operating Peak Current
Continuous
Voltage
Voltage
2 Minutes
Current
KLS4860NT
36-48V
27-60V
400A
160A-240A
KLS4875N
36-48V
27-60V
500A
200A-300A
KLS48100N
36-48V
27-60V
600A
240A-360A
KLS48120N
36-48V
27-60V
700A
280A-420A
KLS7275NT
48-72V
36-86V
450A
180A-270A
KLS7275N
48-72V
36-86V
500A
200A-300A
KLS72100N
48-72V
36-86V
600A
240A-360A
KLS72120N
48-72V
36-86V
700A
280A-420A
KLS72150N
48-72V
36-86V
800A
320A-480A
KLS8475N
48-84V
36-100V
500A
200A-300A
KLS84100N
48-84V
36-100V
600A
240A-360A
KLS84120N
48-84V
36-100V
700A
280A-420A
Chapter 3 Wiring and Installation
3.1 Mounting the Controller
The controller can be mounted in any location; however, it should be kept as clean and dry as possible. If necessary, use a protective cover to prevent water and contaminants from entering.
To ensure the controller delivers its full rated output power, it must be mounted on a clean, flat metal surface and secured using screws in all four mounting holes. Apply silicone grease or another thermally conductive material to the contact surfaces to improve thermal transfer and enhance cooling performance.
Adequate heat sinking and proper airflow are essential to achieve the controller’s maximum power capability.
The case outline and mounting holes’ dimensions are shown below.
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Figure 7: KLS4860NT KLS7275NT mounting holes’ dimensions
(dimensions in millimeters) +/B+/B-/U/V/W:M8
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` Figure 9: KLS-N Series
mounting holes’ dimensions (dimensions in millimeters) +/B+/B-/U/V/W:M8
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Figure 11: With Aluminum Liquid Cooling Heatsink at the bottom mounting holes’ dimensions
(dimensions in millimeters) +/B+/B-/U/V/W:M8
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Kelly High-current series Sinusoidal BLDC Motor Controller User Manual
3.2 Connections
3.2.1 Pin definition of KLS-N Controller
V2.1.2
Figure 10: waterproof connector
DJ7091Y-2.3-11 Pin Definition
1. REV_SW(Pin 14): Reverse switch input. Orange 2. GND(Pin 6): Signal return or power supply return. Black 3. FWD(Pin 12): Forward switch or can be enabled as High speed switch function.
White 4. 12 V(Pin 11): 12 V Supply. Red 5. 12 V (Pin 25): brake switch. Yellowish 6. ECO(Pin 22): Low speed switch. Blue 7. CAN-H(Pin 33): (Optional function). Greenish 8. PWR(Pin 7): Controller power supply (input). Pink 9. CAN-L(Pin 34): (Optional function). Brownish
DJ7091Y-2.3-21 Pin Definition
1. Foot_SW(Pin 15): Throttle switch input. Gray 2. Throttle(Pin 3): Throttle analog input, 0-5 V. Green
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3. GND(Pin 20): Signal return. Black 4. Meter(Pin 8): Copied signal of hall-A sensor. Dark Gray 5. 5 V(Pin 4): 5 V Supply, <40mA. Purple 6. Brake_AN(Pin 2): Brake variable regen or Boost function. Brown 7. 12 V(Pin 11): 12 V Supply. Red
DJ7061Y-2.3-21 Pin Definition
1. GND(Pin 21): Signal return. Black 2. Temp(Pin 1): Motor temperature sensor input. Raddle. 3. 5 V(Pin 5): 5 V Supply, <40mA. Purple 4. Hall A(Pin 18): Hall sensor signal of phase-A. Yellow 5. Hall B(Pin 17): Hall sensor signal of phase-B. Dark Green 6. Hall C(Pin 16): Hall sensor signal of phase-C. Dark Blue
Notes: 1. All GND pins are internally connected. 2. The Meter function outputs the Hall-A sensor signal. 3. By default, the three-gear and three-speed functions cannot be used simultaneously, as
both use the same pin (FWD, Pin 12) for control. 4. Switch signals are valid at 12V. 5. The 12V output (Pin 11) is intended only for switch signals, with a total current not
exceeding 40mA. 6. CAN bus functionality is not included in KLS-N controllers by default. 7. The Boost and Brake Analog Regen functions share the same port (Brake_AN, Pin 2).
When Boost is disabled in the user program, Pin 2 serves as Brake Analog Regen. When Boost is enabled, Pin 2 is used for the Boost function. Due to this port conflict, both functions cannot operate simultaneously on the same port.
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Kelly High-current series Sinusoidal BLDC Motor Controller User Manual
3.2.2 KLS-N Controller Standard Wiring
V2.1.2
Figure 11: KLS-N controller standard wiring (Battery is also used as controller’s power supply)
Caution! 1 Verify all controller wiring before powering on. Double-check connections, especially the B+ and
B- terminals. Incorrect wiring can cause severe damage to the controller. 2 Ensure the B- connection is secure and properly tightened before applying power.The system
contactor or circuit breaker should be connected in series with the B+ line. 3 Important: Any contactors installed in the B+ line must have a diode placed across their coils. This
diode acts as a freewheeling (flyback) diode to protect the controller’s power module. 4 Failure to install this diode may result in serious damage to the controller. 5 Refer to the KLS-N controller standard wiring diagram for proper diode installation.
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3.2.3 Communication Port A 4pin connector is provided to communicate with host for calibration and configuration.
Figure 12: SM-4P connector
3.3 Installation Check List
1. Conduct a visual inspection to ensure all components–such as mounting holes, wiring, and sealing rings–are intact and undamaged.
2. Check the connection between the battery B+ and NC. a) For controllers without a fuse, check the connection between the battery B+ and the controller B+ instead of NC.
3. Check the connection between the battery B- and the controller B-. Ensure the connection is secure and properly tightened.
4. Verify all signal wire connections. Ensure that PWR and GND are properly isolated from each other.
5. Inspect the motor Hall wire connections. Confirm that the 5V and GND wires align correctly with the motor’s interface.
6. Inspect the throttle wire connections. Confirm that the 5V and GND wires align correctly with the throttle’s interface.
7. Check the gear wire connections. By default, the switch signal is valid at 12V.
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Chapter 4 Configuration Program
The KLS Configuration Program enables users to adjust various parameters to suit specific applications, allowing the motor to achieve optimal performance.
The default parameters may not be suitable for all use cases. Ensure all parameters are properly configured before testing to prevent potential hazards. Users can program the controller using either: The PC configuration software (requires Kelly USB cable, or RS232-USB cable and SM-4P adapter). The Android configuration app (requires a Bluetooth Adapter).
Before operating the motor, you must perform an automatic identification process to ensure the controller properly detects and configures the motor parameters.
During this process:
Connect the controller to the battery, motor, and throttle. Ensure PWR (Pin7) is connected to battery B+ to supply power to the controller. Follow the detailed instructions in Chapter 4.2: Automatic Identification Guide.
Notes
1. When configuring parameters in the PC program or Android app, ensure the controller is disconnected from the motor, or at least stop the motor before making changes.
Figure 13 Warning window
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1. The controller may display fault codes while adjusting parameters. This will not affect programming or configuration, but these codes must be cleared before performing the automatic identification process.
2. To connect to a PC Configuration Program:
Use Kelly USB cable, or RS232-USB cable and SM-4P adapter provided by Kelly. During operation, the controller’s PWR must be supplied with >+18V (for 24V
controllers, supply >+8V). Connect GND to battery B-.
3. To connect to an Android device, use a Bluetooth Adapter (sold separately).
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4.1 Connecting to upper host.
You have three ways to connect the controller to host computers or Android devices:
1. Using the Kelly USB cable, connect the SM-4P (Female) from the controller to the USB port on the computer. You may download the Kelly USB Cable driver from our website.(https://media.kellycontroller.com/new/CH341SER.zip)
Figure 14: Kelly USB Cable 2. Using an RS232-USB cable along with the SM-4Pin adapter, connect the SM-4Pin
(Female) from the controller to the USB port on the computer. You may download the USB-RS232 driver from our website. (https://media.kellycontroller.com/new/USB-CONVERTER-RS232-Win10.zip)
Figure 15: RS232-USB (left) and SM 4-Pin (right) adapter 3. Using a Bluetooth Adapter, connect it to the SM-4P (Female) and then connect the
controller to Android devices through Bluetooth. This Bluetooth Adapter can be purchased from our website. (https://kellycontroller.com/shop/usb-adapter)
Figure 16: Bluetooth Adapter 18
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How to Use Auto-Identification
Here is a brief overview of the automatic identification process:
1. Connect the controller and the motor according to the standard wiring diagram (Figure 11). Please make sure there is no load on the motor shaft before starting the programming.
2. Connect the controller to the PC using a Kelly USB cable or a USB to RS232 set. For Android devices, please use the Bluetooth Adapter to connect the controller.
3. 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.
4. 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 shown in the figure below. Please check whether the value of Identification_Angle is 85. An angle value of 85 means that this controller has already completed the automatic identification operation with the motor at the factory. However, it is still necessary to run the automatic identification operation before proceeding.
Figure 17: User program initial interface 19
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5. Enter 170 in the Identification_Angle value, then click the “Write” button. The user program will display a pop-up window indicating that the Write operation succeeded. Then exit from the user program and turn off the power supply.
6. Wait for a few seconds before turning the power supply back on. The motor shaft will attempt to run in random directions. This is a normal operating phenomenon.
7. Wait for about 2-3 minutes. 8. The beeper will sound with error code 3-2, indicating that the automatic identification
operation has completed successfully. You will also see a reset error message on the user program’s monitor screen. 9. Turn off the power supply again, then wait for a few seconds before turning it back on. 10. Connect the controller to the user program. You will see 85 in the Identification_Angle, which means the controller’s auto-identification operation was successful and the motor is ready to run. 11. If the Identification_Angle value is 170, it means the auto-identification process is still ongoing. 12. If no error code is triggered, please do not manually set the Identification_Angle to 85 or restart the power supply. 13. If a constant beep sound lasts for more than 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 manually set Identification_Angle to 85. 14. Before turning off the power supply, make sure that Identification_Angle is not set to 170. Otherwise, the controller will continue attempting identification after the power supply is turned on again. If error codes occur, please exit the user program and try step 6 again. 15. After successful identification, make sure that Identification_Angle is not set to 170. Then, you may turn on the power supply. 16. If the direction of the motor is not what you expected, there is no need to repeat the process. Simply check the “Change Direction” option in the last part of the initial interface, then click the “Write” button and reset. The motor will run in the opposite direction.
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4.3 Program parameters and value
On program’s initial interface, these items are listed:
Number
Parameter
Possible Value
Default Value
Description
Source of Value*
1
Model Name
Controller Model.
Default
2
User Name
User code, to identify controller variants.
Default
3
Serial Number
Serial Number.
Default
4
Software Version
Software Version.
Default
5
Controller Volt
0-144
Controller Voltage(V).
Default
6
Low Volt
18-180
Minimum normal voltage(V), In order to protect the battery, if the battery voltage is lower than this value, the controller will not work.
User Configuration
7
Over Volt
18-180
Maximum normal voltage(V), In order to protect the battery, if the battery voltage is high1er than this value, the controller will not work.
User Configuration
8
Hall
0-1000
Hall Galvanometer Rate(A).
Default
PhaseCurr Max
9
409-2048
AD
The Max AD value of phase current.
Default
The ratio range of the motor phase current to the controller
User
10
Motor_Current
20-100%
100%
peak current.
Configuration
Maximum battery current.
Used to set the upper limit of battery current to protect the
11
Battery_Current
20-100%
50%
battery. A lower value will limit the battery output current more User and protect the battery more effectively. However, if this value Configuration
is too low, it will affect acceleration.
12
Identify Angle
85 / 170
Status of identification:
85:normal operation.
170: A reboot is required to automatically identify the sensor
85
Auto
angle. Once identification is complete, this value will be reset
to 85.
Hall pedal parameter, only valid when TPS type is set to 2.
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TPS Low Err
0-20%
When the actual value is lower than this value, the controller User
0%
will report a TPS type error,
Configuration
20%*5 V=1V
Hall pedal parameter, only valid when TPS type is set to 2.
When the actual value is higher than this value, the controller User
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TPS High Err
80-100%
95%
will report a TPS type error,
Configuration
80%*5 V=4V
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15
TPS Type
1 / 2
16
TPS Dead Low
0-60%
17
TPS Dead High
60-95%
18
TPS Fwd MAP
0-100%
19
TPS Rev MAP
0-100%
20
Brake Type
0 /1 / 2
21
Brake Dead Low
5-40%
22
Brake Dead High
60-95%
23
Max Output Fre
50-1200
24
Max Speed
0-16000
25
Max Fwd Speed
0-100%
26
Max Rev Speed
0-100%
MidSpeed Forw
27
0-100%
Speed
MidSpeed Rev
28
0-100%
Speed
LowSpeed Forw
29
0-100%
Speed
LowSpeed Rev
30
0-100%
Speed%
31
Three Speed
0 / 1 / 2
1 20% 80% 30% 20%
0
20% 80% 1000 4000 100% 100% 50% 30% 50% 30%
0
Throttle Type, 1: 0-5K,resistance pedal; 2: 0,5 V,Hall active pedal;
User Configuration
Throttle Dead Zone Lower Limit,
User
20%*5 V=1V.
Configuration
Throttle Dead Zone Higher Limit,
User
80%*5 V=4V.
Configuration
When moving forward , the MAP value corresponding to
User
throttle midpoint, to adjust throttle response amplitude.
Configuration
When moving backward , the MAP value corresponding to
User
throttle midpoint , to adjust throttle response amplitude.
Configuration
Regen braking mode
0: Switch regen mode.
User
1:0-5K, resistance pedal regen.
Configuration
2:0-5 V, hall active pedal regen.
Brake Dead Zone Lower Limit,
User
20%*5 V=1V.
Configuration
Brake Dead Zone Upper Limit,
User
80%*5 V=4V.
Configuration
Max output Frequency(Hz).
User Configuration
Motor max speed (RPM).
User Configuration
Maximum forward speed to the motor max speed .
User Configuration
Maximum reverse speed to the motor max speed.
User Configuration
Maximum forward speed in the middle speed gear .
User Configuration
Maximum reverse speed in the middle speed gear .
User Configuration
Maximum forward speed in the low speed gear .
User Configuration
Maximum reverse speed in the low speed gear .
User Configuration
Number of speed modes:
0: one speed mode: maximum speed mode.
1:two speed modes: middle speed mode and maximum speed User
mode .
Configuration
2:three speed modes:low speed mode, middle speed mode
and maximum speed mode.
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32
PWM frequency 10 / 16 / 20
16
PWM modulation frequency (Khz)
User Configuration
Kp of Q-ring, the proportional gain in Q-ring current loop, is
mainly effective at speeds below 400 RPM. Increasing this
User
33
IQ Kp
0-32767
500
value will accelerate the response speed but will increase
Configuration
startup jitter; decreasing this value will reduce startup jitter but
will also decrease the response speed.
Ki of Q-ring, the integral gain in Q-ring current loop, is mainly
effective at speeds below 400 RPM. Increasing this value will
User
34
IQ Ki
0-32767
10
improve current accuracy but will increase startup jitter and
Configuration
instability. Decreasing this value will enhance stability and
reduce startup jitter but will also lower current accuracy.
Kp of D-ring, the proportional gain in D-ring speed loop, is
mainly effective at speeds below 400 RPM. Increasing this
User
35
ID Kp
0-32767
1500
value will accelerate the response speed but will increase
Configuration
high-speed jitter; decreasing this value will reduce high-speed
jitter but will also decrease the response speed.
Ki of D-ring, the integral gain in D-ring current loop, is mainly
effective at speeds below 400 RPM. Increasing this value will
User
36
ID Ki
0-32767
30
improve speed accuracy but will increase high-speed jitter
Configuration
and instability. Decreasing this value will enhance stability and
reduce high-speed jitter but will also lower speed accuracy. Kp of Q-ring, the proportional gain in Q-ring current loop, is
mainly effective at speeds above 400 RPM. Increasing this
User
37
HS_ACQR_Kp
0-32767
2000
value will accelerate the response speed but will increase
Configuration
startup jitter; decreasing this value will reduce startup jitter but
will also decrease the response speed.
Ki of Q-ring, the integral gain in Q-ring current loop, is mainly
38
HS_ACQR_Ki
0-32767
effective at speeds above 400 RPM. Increasing this value will
User
60
improve current accuracy but will increase startup jitter and
Configuration
instability. Decreasing this value will enhance stability and
reduce startup jitter but will also lower current accuracy.
Kp of D-ring, the proportional gain in D-ring speed loop, is
mainly effective at speeds above 400 RPM. Increasing this
User
39
HS_ACDR_Kp
0-32767
5000
value will accelerate the response speed but will increase
Configuration
high-speed jitter; decreasing this value will reduce high-speed
jitter but will also decrease the response speed.
Ki of D-ring, the integral gain in D-ring current loop, is mainly
effective at speeds above 400 RPM. Increasing this value will
User
40
HS_ACDR_Ki
0-32767
100
improve speed accuracy but will increase high-speed jitter
Configuration
and instability. Decreasing this value will enhance stability and
reduce high-speed jitter but will also lower speed accuracy.
23
Kelly High-current series Sinusoidal BLDC Motor Controller User Manual
V2.1.2
41
BRK_AD Brk
0-50%
42
Anti-theft
0-30%
43
Brk_Speed Limit
0-500
44
RLS_TPS Brk
0-50%
45
NTL Brk
0-50%
46
Accel Time
1-250
47
Accel Rls Time
1-250
48
Brake Time
1-250
49
Brake Rls Time
1-250
50
BRK_SW Brk
0-50%
51
Change Dir Brk
0-50%
52
Compensation
0-100%
53
IVT BRK Max
0-10000
54
IVT BRK Min
0-5000
55
Torque Speed Kp
0-10000
56
Torque Speed Ki
0-500
0% 15%
0 0% 0% 5 1 5 1 10% 5% 20% 10000 50
3000
80
Brake pedal regen’s regen strength,
User
0= no regen.
Configuration
When the anti-theft function is activated, the percentage of the User
motor’s locking current to the maximum current.
Configuration
Minimum motor speed to activate regen brake (RPM), RPM User
below this value will exit regen.
Configuration
Pedal releasing regen `s regen strength,
User
0= no regen.
Configuration
Neutral gear regen `s regen strength,
User
0= no regen.
Configuration
Torque mode accelerate Time,
User
the time of torque from 0 to max,(X0.1second)
Configuration
Torque mode accelerate release delay Time,
User
the time of torque from max to 0,(X0.1second)
Configuration
Torque mode Brake Time,
User
the time of Brake Torque from 0 to max,(X0.1second)
Configuration
Torque mode Brake release Time,
User
the time of Brake Torque from max to 0,(X0.1second)
Configuration
Switch regen `s regen strength.
User
0= no Switch regen.
Configuration
Change direction regen`s regen strength.
User
0= no Change direction regen.
Configuration
Compensation current of anti-slip function.
User Configuration
Maximum motor speed for enable Change direction
User
regen(RPM)
Configuration
Minimum motor speed for enable Change direction regen
User
(RPM) Kp of Q-ring in torque mode,
Configuration
the proportional gain in Q-ring current loop, is mainly effective
at speeds below 400 RPM. Increasing this value will
User
accelerate the response speed but will increase startup jitter; Configuration
decreasing this value will reduce startup jitter but will also
decrease the response speed.
Ki of Q-ring in torque mode
the integral gain in Q-ring current loop, is mainly effective at
speeds below 400 RPM. Increasing this value will improve current accuracy but will increase startup jitter and instability. Decreasing this value will enhance stability and reduce
User Configuration
startup jitter but will also lower current accuracy.
24
Kelly High-current series Sinusoidal BLDC Motor Controller User Manual
V2.1.2
57
Speed Err Limit
50-4000
58 Motor Poles 0-1000
59
Motor Poles
2-128
1000 80 8
Limit of Kp and Ki in torque mode, need to be adjusted at same time when adjusting Kp and Ki in torque mode.
Motor Current when identification(A)
Number of motor poles, equal to 2* pole pairs. When used for hub motors, reducing this value by multiples, such as from 8 to 4, can improve the speed measurement accuracy.
User Configuration User Configuration
User Configuration
Speed Sensor
60
2 /3/ 4
Type
61
Resolver Poles
2-32
62
Min Excitation
0-100
Sensor Type:
2. Hall sensor 2
3. Magnetic encoder.
User Configuration
4. Linear Hall sensorsine/cosine sensors
Reserved.
User Configuration
Minimum excitation coefficient (A)
This value affects the current and maximum speed of the
motor when the field weakening function is enabled.
User
0
When this value = 0, the field weakening function has no
Configuration
actual effect
63
Motor Temp
0 / 1 / 2
64
High Temp Cut °C
60-170
65
Resume °C
60-170
66
High Temp Str°C
0-170
67
High Temp weak
0-100%
68
Line Hall Zero
1-1023
Linear Hall
69
1-1024
Amplitude
0
150 110 100 50%
Temperature sensor type,
0:none.
User
1: KTY84-130 and KTY84-150
Configuration
2: KTY83-122
Temperature for triggering the motor’s high temperature cut User
off.
Configuration
When the temperature drops back to this value, high
User
temperature resume will be triggered.
Configuration
starting temperature for high-temperature weakening. (°C)
User Configuration
The strength of high-temperature weakening (%)
User Configuration
Zero point of sine/cosine sensor signal, this value / 1024 * 5 = actual voltage value (Volts). Available for sine/cosine sensor
User Configuration
Signal amplitude of sine/cosine sensor signal.
this value / 1024 * 5 = actual voltage value (Volts). When this value is below 153.6 or above 256,the signal voltage is error.
User Configuration
Available for sine/cosine sensor
25
Kelly High-current series Sinusoidal BLDC Motor Controller User Manual
V2.1.2
An error will be reported when the amplitude of the
70
Line Hall High
1-1023
sine/cosine sensor signal exceeds this value. this value / 1024 * 5 = actual voltage value (Volts).
User Configuration
Available for sine/cosine sensor
An error will be reported when the amplitude of the
71
Line Hall Low
1-1023
sine/cosine sensor signal is below this value. this value / 1024 * 5 = actual voltage value (Volts).
User Configuration
Available for sine/cosine sensor
Swap phase function status
0: disabled
Swap Motor
72
0 / 1 /255
0
1: enabled,
Phase
255: error.
Default
Available for sine/cosine sensor
Synchro Initial Angle , defines the reference point of the
Synchro Initial
73
0-65535
8192
position when sensor type is set to 4.
Angle
Available for sine/cosine sensor
Default
74
0° Hall value
0-7
2
Hall sensor sequence value at motor electrical angle 0°.
Auto
75
60° Hall value
0-7
6
Hall sensor sequence value at motor electrical angle 60°
Auto
76
120°Hall value
0-7
4
Hall sensor sequence value at motor electrical angle 120°
Auto
77
180°Hall value
0-7
5
Hall sensor sequence value at motor electrical angle 180°
Auto
78
240°Hall value
0-7
1
Hall sensor sequence value at motor electrical angle 240°
Auto
79
300°Hall value
0-7
3
Hall sensor sequence value at motor electrical angle 300°
Auto
Forward HA Rising
80
0-7
edge
Forward Hall-A Rising edge 6
sequence value
Auto
Forward HA
81
0-7
Falling edge
Forward Hall-A Falling edge 1
sequence value
Auto
Reverse HA Rising
82
0-7
edge
Reverse Hall-A Rising edge 5
sequence value
Auto
Reverse HA
83
0-7
Falling edge
Reverse Hall-A Falling edge 2
sequence value
Auto
84
Brake_SW_Level
0-255
Brake_SW_Level
Default
85
J CAN Address
0-255
CAN Address, when there are multiple CANs, different 5
addresses need to be set
User Configuration
Startup High pedal function ,
Checked: From powerup, when the first time throttle being
checked/
User
86
Startup H-Pedal
checked pressed, the controller will report a high pedal error to prevent
unchecked
Configuration
accidental starting, need to step on the pedal again to start.
Brake High-pedal function
checked/
User
87
Brake H-Pedal
unchecked Checked: When press the brake and throttle at the same time,
unchecked
Configuration
he controller will report a high pedal error to stop running.
26
Kelly High-current series Sinusoidal BLDC Motor Controller User Manual
V2.1.2
Neutral High-pedal function
checked/
Checked: the first time throttle being pressed after switching User
88
NTL H-Pedal
unchecked
unchecked
gears, the controller will report a high pedal error to prevent Configuration
accidental starting, need to step on the pedal again to start.
Joystick throttle
Checked: enable joystick throttle,
Its range:
checked/
89
Joystick
unchecked 0-2.5 V: forward
unchecked
2.5 V: neutral
User Configuration
2.5 V-5 V: backward.
Has same range of dead zone as TPS dead zone.
Three-gear function
Three Gears
checked/
Check: Enable three operating gears:
90
unchecked
Switch
unchecked
Forward, Neutral, Reverse.
User Configuration
Uncheck: Forward only.
Boost function,
Checked: enable boost switch,
checked/
Connect Brake_AN (PIN2) to 12 V to start boost.
User
91
Boost
unchecked
unchecked
Unchecked: Connect Brake_AN (PIN2) to 12 V to start switch Configuration
regen.
Thorttle switch
checked/
User
92
Foot Switch
unchecked Checked: Connect Foot_SW to 12 V to enable throttle, so
unchecked
Configuration
motor can start.
Defining which is the effective level of the switch.
checked/
Checked: high level=enable.
93
SW Level
checked
unchecked
Unchecked: low level=enable.
Default
Controller type
checked/
94
0,HIM;1,KIM
checked Checked: KIM.
unchecked
Unchecked: HIM.
Default
Cruise function
Check: Enable the cruise function. Press and hold the
checked/
accelerator for more than 3 seconds to enter the cruise mode. User
95
Cruise
unchecked
unchecked
If the eRPM is lower than 4000, the controller will
Configuration
automatically exit the cruise mode.
Anti-theft function
Checked: enable anti-theft function,
checked/
User
96
Anti-theft
unchecked Need to connect to external anti-theft device. When the alarm
unchecked
Configuration
is triggered, the motor will resist being turned.
27
Kelly High-current series Sinusoidal BLDC Motor Controller User Manual
V2.1.2
97
Anti-Slip
98
Change Direction
Source of Value *:
checked/ unchecked
checked/ unchecked
unchecked unchecked
Anti-Slip function Checked: enable anti-slip function, The motor will resist rotation to prevent the vehicle from moving due to external forces. Change Direction function Checked: Swap the forward and backward directions. Unchecked: no swap. Used to correct the motor from moving opposite direction after identification
User Configuration
User Configuration
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 and cannot be modified by the user program.
Chapter 5 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, including, but not limited to, proper training, wearing eye protection, avoiding loose clothing, hair, and jewelry, and 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. For fanned models, routine fan maintenance is required, including ensuring the fan
rotates normally and cleaning the dust from the fan.
28
Kelly High-current series Sinusoidal BLDC Motor Controller User Manual
V2.1.2
Table 1: Error Codes
Buzzer Error Codes
Error code
Explanation
Solution
1. Check Phase line or Hall line.
1, 1
¤
¤
Auto-Identification2. Check Hall power line(+5 V and GND).
failed
3. The motor load maybe too high. Please unload the
motor before proceeding with identification.
1. Battery voltage is too high for the controller. Check
battery volts and controller configuration.
1, 2 ¤ ¤¤ Over voltage error2. Regeneration over-voltage. Controller will limit regen or
stop regen. please reduce the regen ratio in
configuration.
Battery voltage is too low, please check the battery and
recharge.
1, 3 ¤ ¤¤¤ Low voltage error When the battery voltage continuously exceeds the low
voltage cut-off value for 5 seconds, the controller will
resume normal operation.
The controller did
1, 4 ¤ ¤¤¤¤ not receive CAN Resend CAN commands from VCU.
commands
The motor did not reach 25eRPM within 2 seconds of
2, 1 ¤¤ ¤
Motor stall starting. Please check the Hall signal lines and the phase
line connections.
1. Check the connection between PWR and B+(For
8080N series, check connection between PWR and
+12 V; GND and -12 V).
2. The load on the 5 V or 12 V power supply could be too
2, 2
¤¤ ¤¤
Internal voltage error
heavy, ensure that the measured voltage of the 5 V power supply is not less than 4V and the voltage of the 12 V power supply is not less than 8V. The lower these
values are, the heavier the load on the power supply.
3. If none of the above issues are present, the internal
power module of the controller may be damaged. The
controller needs to be sent back to the factory.
2, 3
¤¤
¤¤¤
Over
temperature
The controller temperature is too high, Please wait until it restore to 80°C.
about
to
stop.
Throttle signal is higher than the value of
2, 4 ¤¤
¤¤¤¤
Throttle error at “TPS_dead_low”at power-on. Release the throttle and power on press again or adjust the TPS_dead_low value. If still can’t
fix the issue, check if the throttle is functioning properly.
29
Kelly High-current series Sinusoidal BLDC Motor Controller User Manual
V2.1.2
3, 1 ¤¤¤ ¤
Reserved
3, 2 ¤¤¤ ¤¤
Internal reset error
Current is too high or current fluctuations are too large. Reduce the phase current and check if the 5 V and 12 V power supplies are normal.
May occur after TPS_Type being set to 2.
Hall throttle is 1. The throttle might have an internal short circuit or the
3, 3 ¤¤¤ ¤¤¤
open or
ground wire might be disconnected.
short-circuit 2. Set TPS_High_Err to 95 , check the throttle and its
wiring, then restart to fix the issue.
1. Speed sensor type error,customers may set the
3, 4 ¤¤¤ ¤¤¤¤
Angle sensor error
2. 3.
correct sensor type through user program or App. Incorrect wiring. Speed sensor is damaged or defective. Or feedback
signal is erratic.
4, 1
¤¤¤¤ ¤
Switch-direction 1. Throttle is not at 0 when switching motor direction.
error
2. Motor rotation speed is above 50RPM.
4, 2 ¤¤¤¤ ¤¤
Reserved
May occur after motor temp being set to 1 or 2.
4, 3
¤¤¤¤
¤¤¤
Motor
The Motor temperature has exceeded the configured
over-temperature maximum value. The controller will shut down until the
motor temperature cools down.
Hall
4, 4 ¤¤¤¤ ¤¤¤¤ Galvanometer Hall galvanometer inside the controller is damaged.
sensor error
Error codes can be read through PC software or Android app.
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
30
Documents / Resources
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Kelly Controls KLS-N Series High Current Sinusoidal BLDC Motor Controllers [pdf] User Manual KLS4860NT, KLS4875N, KLS48100N, KLS48120N, KLS7275NT, KLS7275N, KLSAA72100N, KLS72120N, KLS72150N, KLS8475N, KLS84100N, KLS84120N, KLS-N Series High Current Sinusoidal BLDC Motor Controllers, KLS-N Series, High Current Sinusoidal BLDC Motor Controllers, Sinusoidal BLDC Motor Controllers, Motor Controllers, Controllers |