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Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User

’s Manual V1.11

32

2,Please connect the controller to user program by using an USB to RS232 cable and SM-4A
DB9(RS232) Converter.

Customers also can use a Z-TEK USB to RS232 cable and SM-4A DB9(RS232) Converter to
connect the controller to an Android Tablet.

The third option is customers can buy our Bluetooth converter to connect the controller to
Android Phone.

We don‟t have to use SM-4A to DB9(RS232) converter any more when you use

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Summary of Contents for KLS-180N

Page 1: ...80NPS KLS96401 8080N KLS96401 8080NPS KLS96501 8080N KLS96501 8080NPS KLS96601 8080N KLS96601 8080NPS KLS12201 8080N KLS12201 8080NPS KLS12301 8080N KLS12301 8080NPS KLS12401 8080N KLS12401 8080NPS KLS14201 8080N KLS14201 8080NPS KLS14301 8080N KLS14301 8080NPS KLS14401 8080N KLS14401 8080NPS KLS12501 180N KLS12501 180NPS KLS12601 180N KLS12601 180NPS KLS14501 180N KLS14501 180NPS KLS14601 180N KL...

Page 2: ...iring and Installation 7 3 1 Mounting the Controller 7 3 2 Connections 11 3 3 Installation Check List 16 Chapter 4 Programmable Parameters 17 4 1 Step 1 18 4 2 Step 2 23 4 3 Step 3 24 4 4 How to use Identification angle operation for KLS 8080N and KLS 180N controller 26 4 5 How to use Identification angle operation for KLS 8080NPS and KLS 180NPS controller 31 Chapter 5 Maintenance 37 5 1 Cleaning ...

Page 3: ...er 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...

Page 4: ...ase 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 ...

Page 5: ...om our website This small converter is only useful for KLS controller 23 Can support three speed function on the latest version 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 monito...

Page 6: ...ed 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 2 3 Specifications Frequency of Operation 10KHz or 20kHz Standby Battery Current 0 5mA 5V or 12V Sensor Supply Current 40mA Controller supply voltage range PWR 8V to 30V for pin7 and pin6 which must be isola...

Page 7: ...oltage Volt KLS72501 8080N NPS 500 200 24 72 86 KLS72601 8080N NPS 600 240 24 72 86 KLS72701 8080N NPS 700 280 24 72 86 KLS96301 8080N NPS 300 120 24 96 115 KLS96401 8080N NPS 400 160 24 96 115 KLS96501 8080N NPS 500 200 24 96 115 KLS96601 8080N NPS 600 240 24 96 115 KLS12201 8080N NPS 200 80 24 120 144 KLS12301 8080N NPS 300 120 24 120 144 KLS12401 8080N NPS 400 160 24 120 144 KLS14201 8080N NPS ...

Page 8: ...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 ...

Page 9: ...Kelly KLS 8080N NPS KLS 180N NPS Sinusoidal BLDC PMSM Controller User s Manual V1 11 8 Figure2 KLSxx301 8080N NPS mounting holes dimensions dimensions in millimeters B B U V W M8 ...

Page 10: ...PS KLS 180N NPS Sinusoidal BLDC PMSM Controller User s Manual V1 11 9 Figure3 KLSxx401 8080N NPS KLSxx501 8080N NPS KLSxx601 8080N NPS KLSxx701 8080N NPS mounting holes dimensions dimensions in millimeters B B U V W M8 ...

Page 11: ...Kelly KLS 8080N NPS KLS 180N NPS Sinusoidal BLDC PMSM Controller User s Manual V1 11 10 Figure4 KLS 180N NPS mounting holes dimensions dimensions in millimeters B B U V W M8 ...

Page 12: ...his 12V only can be used for LED or switch signals 3 Boost and Brake analog regeneration mode used the same pin as pin2 When Boost is disabled in the user program the pin2 can be used as brake variable regen mode When Boost is enabled the brake analog regen mode is inactivated automatically Both Boost and Brake variable regen mode can not be used at the same time Figure 4 waterproof connector ...

Page 13: ...mperature sensor input Raddle 5 5V 5V supply output 40mA Purple 18 Hall A Hall phase A Yellow This is Sine signal input on KLS 8080NPS and KLS 180NPS 17 Hall B Hall phase B Dark Green This is Cosine signal input on KLS 8080NPS and KLS 180NPS 16 Hall C Hall phase C Dark Blue There is no hall C signal input on KLS 8080NPS and KLS 180NPS Notes 1 All RTN pins are internally connected 2 Meter function ...

Page 14: ...Kelly KLS 8080N NPS KLS 180N NPS Sinusoidal BLDC PMSM Controller User s Manual V1 11 13 3 2 2 Standard Wiring Figure 5 KLS 8080N KLS 180N controller standard wiring ...

Page 15: ...Kelly KLS 8080N NPS KLS 180N NPS Sinusoidal BLDC PMSM Controller User s Manual V1 11 14 Figure 6 KLS8080NPS KLS180NPS controller standard wiring ...

Page 16: ...t signal of the pin supplies the second braking function of the controller Figure 7 Wiring of brake switch 12V 12V is provided by external source Figure 8 Wiring of brake switch 12V 12V is provided by KLS 8080N or KLS 180N controller on pin11 Figure 9 Wiring diagram for motor temperature sensor NOTE KLS controller can support KTY84 150 KTY84 130 KTY83 122 thermistors ...

Page 17: ...ller 3 3 Installation Check List Before operating the vehicle complete the following checkout procedure Use LED 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 ...

Page 18: ...ogrammable 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 or Android App The Android Tablet is preferred Fi...

Page 19: ...173 18 173 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 outp...

Page 20: ...es 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 type at 2 As the same goes it is valid to adj...

Page 21: ...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 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 ...

Page 22: ...le 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...

Page 23: ...s not operated at all The boost function is still based on limiting of the motor current and battery current settings in user program If disabled the controller can provide brake sensor regen mode on the same pin as pin2 In simple boost and brake analog regen used the same pin as pin2 Suggestion Set according to the practical situation factory default is Disable So the default function is brake va...

Page 24: ...ere is a current requirement for identification operation If the motor rated power is very high please increase this parameter to a higher value Otherwise please keep it at 80 by default If the motor power is very low such as hundreds of watts please reduce this parameter to lower value to match the low power motor for identification angle operation 2 Motor Poles Motor Poles The pair pole number 2...

Page 25: ...Cosine sensors is from 1 9V to 4 1V 3 1 1 1 9V 3 1 1V 4 1V Value Range 0 1023 maps 0 5V 8 Line Hall High Err It is only useful when the speed sensor is at 4 If the signal output of Sine Cosine speed sensor is above this setting the controller will report hall error Please adjust Line Hall High Err to a higher value to eliminate this error Value Range 0 1023 maps 0 5V 9 Line Hall Low Err It is only...

Page 26: ...tory set is 10 8 BRK_AD Brk It is used to adjust the max regen percentage of brake variable regen mode This regen mode doesn t need brake switch to support any more for KLS controller 9 Torque Speed KP Speed Percent Kp in Torque Mode Range 0 10000 Factory set is 3000 Torque Speed KI Speed Integral Ki in Torque Mode Range 0 500 Factory set is 80 Speed Err Limit Speed Error Limit in Torque Mode Rang...

Page 27: ... Thermistor is optional Default to KTY84 130 150 or KTY83 122 When controller temp item shows 246 in monitor screen of user program it is normal This item is only useful for internal calculation for MCU 246 is about 11 degrees in environment 4 4 How to use Identification angle operation for KLS 8080N and KLS 180N controller We must do Identification angle operation before running motor for all KLS...

Page 28: ...Kelly KLS 8080N NPS KLS 180N NPS Sinusoidal BLDC PMSM Controller User s Manual V1 11 27 2 Please connect the controller to user program by using an USB to RS232 cable and SM 4A DB9 RS232 Converter ...

Page 29: ...A to DB9 RS232 converter any more when you use Bluetooth converter for programming the controller 3 Please download the controller user program from our website for free www kellycontroller com support php Please install the user program in your computer Tablet or Phone 4 Please turn on the key switch so that the controller can get power supply from B B and Pin7 Pin6 Please try to open the user pr...

Page 30: ...ry to run on directions randomly It is normal because the controller is doing Identification angle operation 7 Please wait about 2 3 minutes 8 If the identification angle operation is finished the motor will stop completely Please try to reset the power and try to connect the controller to user program or APP again And you will see reset error message in the monitor screen of user program 9 Please...

Page 31: ...odes you can not write it back to 85 by manual Please wait longer time until the error codes occur Please don t keep 170 in the identification angle item when you want to turn off the power supply Otherwise the controller will try to keep doing identification operation all the time as long as you turn on power supply again When the error codes occur please quit from user program Please try again f...

Page 32: ...ed for BLDC or PMSM motor with Sin Cosin sensors By default the speed sensor type is set at 4 from factory setting for KLS 8080NPS and KLS 180NPS controller 1 Please hook up the controller for identification angle operation according to the wiring diagram below Please make sure there is no load on the motor shaft before starting the programming The KLS 8080NPS is designed by opto isolated technolo...

Page 33: ...SB to RS232 cable and SM 4A DB9 RS232 Converter Customers also can use a Z TEK USB to RS232 cable and SM 4A DB9 RS232 Converter to connect the controller to an Android Tablet The third option is customers can buy our Bluetooth converter to connect the controller to Android Phone We don t have to use SM 4A to DB9 RS232 converter any more when you use ...

Page 34: ...gram in your computer or other devices Then you may try to click Read button in user program or App You will see the first picture of user program Please check whether the Identification Angle item is at 85 or not It is correct if identification angle item is at 85 4 2 Because this is a KLS 8080NPS controller based on Sin Cosin speed sensor We need to configure the correct parameters for Sin Cosin...

Page 35: ...Please click Motor button in the user program Line hall zero The line hall zero point is at 3Vdd 5 3 5V 5 3 0V So we need to fill 3 1023 5 613 8 614 for Line hall zero parameter instead of 508 in the user program Line hall amplitude The document showed the Amplitude is 1 1V 0 2V We think the amplitude is 1 1V for now So we need to fill 1 1 1023 5 225 for line hall amplitude instead of 410 in the u...

Page 36: ...settings And we need to do identification angle operation each time after you changed the settings We need to reset the power supply each time when we change the settings and do the identification angle operation We may wait a few seconds to reset the power supply after change the settings 5 Please fill 170 in the identification angle item And please click the write button The user program will gi...

Page 37: ...ease quit from user program Please try again from step 6 14 Please don t keep 170 in identification angle item before power supply is turned on after the identification operation is successful 15 If the direction of the motor is not what you expected please don t try to do Identification angle operation again You just need to enable Change Direction item in the first picture of user program Please...

Page 38: ...re the connections to the bus bars if fitted are tight To avoid physically stressing the bus bars use two well insulated wrenches 5 2 Configuration You can configure the controller with a host computer through either an RS232 or USB port Disconnect motor wiring from controller for configuring existing parameters in the user program or Android APP If this operation is too much extra job for you ple...

Page 39: ...nsors in the user program Table 1 ERROR CODES Buzzer Error Codes Code Explanation Solution 1 1 Automatic error identification 1 Wrong wiring of motor phase line or hall Please suspend the motor when enable Auto Identify function 1 2 Over voltage error 2 Battery voltage is too high for the controller Check battery volts and configuration 3 Regeneration over voltage Controller will have cut back or ...

Page 40: ...ow battery voltage This can happen during normal operation 3 3 Hall throttle is open or short circuit When the throttle is repaired a restart will clear the fault 3 4 Angle sensor error 1 Speed sensor type error customers may set the correct sensor type through user program or App Please download how to use Identification function instruction from our website 2 Incorrect wiring 3 Speed sensor is d...

Page 41: ...DC PMSM Controller User s Manual V1 11 40 Contact Us Kelly Controls Home Page http www KellyController com Download user manual instructions and user program www kellycontroller com support php E mail Sales Kelly Controls com Phone 01 224 637 5092 ...

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