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

’s Manual

V1.13

14

3.2.3 Optional wiring of KLS-8080N/NPS controller

The 12V input 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 controller on pin11

Figure 9: Wiring diagram for motor temperature sensor

NOTE:

KLS controller can support KTY84-150, KTY84-130,KTY83-122 thermistors.

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Summary of Contents for KLS11401-8080N

Page 1: ...8080N KLS72501 8080NPS KLS72601 8080N KLS72601 8080NPS KLS72701 8080N KLS72701 8080NPS KLS96401 8080N KLS96401 8080NPS KLS96501 8080N KLS96501 8080NPS KLS96601 8080N KLS96601 8080NPS KLS11401 8080N KL...

Page 2: ...Kelly KLS 8080N NPS Sinusoidal BLDC PMSM Controller User s Manual V1 13 Feb 2023...

Page 3: ...Wiring and Installation 7 3 1 Mounting the Controller 7 3 2 Connections 10 3 3 Installation Check List 15 Chapter 4 Programmable Parameters 16 4 1 Step 1 17 4 2 Step 2 22 4 3 Step 3 23 4 4 How to use...

Page 4: ...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 cond...

Page 5: ...ltage 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 al...

Page 6: ...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 d...

Page 7: ...y 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 Bat...

Page 8: ...see note KLS72501 8080N NPS 500 200 24 72 86 A KLS72501 8080N NPS 500 250 24 72 86 B KLS72601 8080N NPS 600 240 24 72 86 A KLS72601 8080N NPS 600 300 24 72 86 B KLS72701 8080N NPS 700 280 24 72 86 A K...

Page 9: ...ts 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 surfa...

Page 10: ...Kelly KLS 8080N NPS Sinusoidal BLDC PMSM Controller User s Manual V1 13 8 Figure 2 With Aluminum Liquid Cooling Heatsink at the bottom mounting holes dimensions dimensions in millimeters B B U V W M8...

Page 11: ...Kelly KLS 8080N NPS Sinusoidal BLDC PMSM Controller User s Manual V1 13 9 Figure3 With Sealed Aluminium Housing mounting holes dimensions dimensions in millimeters B B U V W M8...

Page 12: ...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...

Page 13: ...1 Temp Motor temperature 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 17 Hall B Hall phase B Dark Green This is Cosine s...

Page 14: ...Kelly KLS 8080N NPS Sinusoidal BLDC PMSM Controller User s Manual V1 13 12 3 2 2 Standard Wiring Figure 5 KLS 8080N controller standard wiring...

Page 15: ...Kelly KLS 8080N NPS Sinusoidal BLDC PMSM Controller User s Manual V1 13 13 Figure 6 KLS8080NPS controller standard wiring...

Page 16: ...f 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...

Page 17: ...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 w...

Page 18: ...le 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 recom...

Page 19: ...73 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...

Page 20: ...ll 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...

Page 21: ...t 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 spee...

Page 22: ...ontroller 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...

Page 23: ...erated 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...

Page 24: ...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 i...

Page 25: ...ensors 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...

Page 26: ...t 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...

Page 27: ...Note 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...

Page 28: ...Kelly KLS 8080N NPS Sinusoidal BLDC PMSM Controller User s Manual V1 13 26 2 Please connect the controller to user program by using an USB to RS232 cable and SM 4A DB9 RS232 Converter...

Page 29: ...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 Pl...

Page 30: ...un 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...

Page 31: ...u 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...

Page 32: ...default the speed sensor type is set at 4 from factory setting for KLS 8080NPS controller 1 Please hook up the controller for identification angle operation according to the wiring diagram below Pleas...

Page 33: ...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 Phon...

Page 34: ...vices 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 id...

Page 35: ...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 pr...

Page 36: ...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 opera...

Page 37: ...it 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 dire...

Page 38: ...onnections 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 throug...

Page 39: ...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 Au...

Page 40: ...ery 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 e...

Page 41: ...Controller User s Manual V1 13 39 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...

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