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Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User

’s Manual

V 1.10

9

3.2.2 Standard

Wiring of KLS8080N/NPS Controller

Figure 3: KLS8080N

controller standard wiring

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Summary of Contents for KLS12201-8080N

Page 1: ...1 10 Feb 2022 KLS72501 8080N KLS72601 8080N KLS72701 8080N KLS96501 8080N KLS96601 8080N KLS12201 8080N KLS12301 8080N KLS14201 8080N KLS14301 8080N KLS14401 8080N KLS72501 8080NPS KLS72601 8080NPS KLS72701 8080NPS KLS96501 8080NPS KLS96601 8080NPS KLS12201 8080NPS KLS12301 8080NPS KLS14201 8080NPS KLS14301 8080NPS KLS14401 8080NPS ...

Page 2: ...Chapter 3 Wiring and Installation 6 3 1 Mounting the Controller 6 3 2 Connections 7 3 3 Installation Check List 12 Chapter 4 Programmable Parameters 13 4 1 Step 1 14 4 2 Step 2 19 4 3 Step 3 20 4 4 How to use Identification angle operation for KLS 8080N controller 22 4 5 How to use Identification angle operation for KLS 8080NPS controller 27 Chapter 5 Maintenance 33 5 1 Cleaning 33 5 2 Configurati...

Page 3: ...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 controller now The APP software is based on Tablet with And...

Page 4: ... TEK USB to RS232 cable allows for configuration programming and software upgrades using the tablet which must be based on Android OS now People can do the same things on PC software by using a standard USB to RS232 cable instead 9 Provision of a 5 volt and 12 volt output to supply various kinds of hall sensors 10 5 switch inputs which are activated by connection to 12V Default to throttle switch ...

Page 5: ...7 Current control loop 8 Hardware over current protection 9 Hardware over voltage protection 10 Configurable limit for motor current and battery current 11 Low EMC 12 Battery protection current cutback warning and shutdown at configurable high and low battery voltage 13 Rugged aluminum housing for maximum heat dissipation and harsh environment 14 Rugged high current terminals and rugged aviation c...

Page 6: ...on of Kelly KLS motor controllers KLS 8080N NPS KLS Kelly BLDC motor controller based on sinusoidal waveform KLS8080N is supposed to work with brushless motor with three hall sensors while KLS8080NPS can work with Sin Cosin speed sensors There are 5V Sin Cosin and GND I O ports for brushless motor with Sin Cosin speed sensors I KLS8080N is designed by opto isolated technology We specify 8 30V for ...

Page 7: ...nants 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 in Figu...

Page 8: ...w This 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 2 KLS8080N NPS waterproo...

Page 9: ...lack 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 KLS8080NPS 17 Hall B Hall phase B Dark Green This is Cosine signal input on KLS8080NPS 16 Hall C Hall phase C Dark Blue There is no hall C signal input on KLS8080NPS Notes 1 All RTN pins are internally connected 2 Meter function is to copy either of hall se...

Page 10: ...Kelly KLS8080N NPS Sinusoidal Brushless Motor Controller User s Manual V 1 10 9 3 2 2 Standard Wiring of KLS8080N NPS Controller Figure 3 KLS8080N controller standard wiring ...

Page 11: ...Kelly KLS8080N NPS Sinusoidal Brushless Motor Controller User s Manual V 1 10 10 Figure 4 KLS8080NPS controller standard wiring ...

Page 12: ...al of the pin supplies the second braking function of the controller Figure 5 Wiring of brake switch 12V 12V is provided by external source Figure 6 Wiring of brake switch 12V 12V is provided by KLS8080N controller on pin11 Figure 7 Wiring diagram for motor temperature sensor NOTE KLS controller can support KTY84 150 KTY84 130 KTY83 122 thermistors ...

Page 13: ...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 well ...

Page 14: ...ve it in a clear area It should have smooth acceleration and good power Chapter 4 Programmable 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 Custo...

Page 15: ...controller 90V 96V controller 120V 120V controller 136V 144V controller 180V Controller Rated voltage Under Voltage Range V Over Voltage Range V 72V 18 90 18 90 96V 18 120 18 120 120V 18 136 18 136 144V 18 180 18 180 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 ...

Page 16: ...n adjust the threshold voltage below or above 0 5V The controller will report the 3 3 code to protect the system according to different types 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...

Page 17: ...e 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 supposed to enable F N R control When this item is disabled we can u...

Page 18: ...k 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 If you don t choose the joystick you operated the throttle in this way The motor speed will increase when the throttle is from 0V to 5V If you enable joystick for this controller...

Page 19: ...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 variable regen mode 25 Foot switch It is used for microswitch If enabled the controller will only accept the throttle signal after received the valid foot switch signal If there is no foot switch signal the controller will ignore the throttle signal...

Page 20: ... Range 2 128 Suggestion Set according to the real motor poles on the nameplate of the motor factory default is at 8 3 Speed Sensor Type Speed Sensor Type 2 Hal 3 Resolver Reservation 4 Line Hall Range 2 or 4 Different sensors type By defualt it is set at 2 If you have a motor with 5V Sin Cosin GND speed sensors please choose it at 4 And please inquire the KLS 8080NPS model before ordering KLS 8080...

Page 21: ...nly useful when the speed sensor is at 4 If the signal output of Sine Cosine speed sensor is below this setting the controller will report hall error also Please adjust Line Hall Low Err to a lower value to eliminate this error Value Range 0 1023 maps 0 5V 4 3 Step 3 1 RLS_TPS Brk RLS TPS Braking Percent the percent of Releasing Pedal BRK in max braking Range 0 50 This is used to adjust the regen ...

Page 22: ... 50 4000 Factory set is 1000 These three parameters are used for PID adjustment If you think the acceleration performance is very very strong please adjust them to a lower value respectively 10 Change Dir brake Value range Enable and Disable It is only useful when you Enable the joystick function If you want to get swift direction changing by using joystick function you may enable Change Dir brake...

Page 23: ...ntification angle operation for KLS 8080N controller We must do Identification angle operation before running motor for all KLS controllers The Identification angle operation can be done in PC program or Android App Tablet or Cell Phone KLS 8080N controller is designed for BLDC motor with three hall sensors By default the speed sensor type is set at 2 from factory setting for KLS 8080N controller ...

Page 24: ...Kelly KLS8080N NPS Sinusoidal Brushless Motor Controller User s Manual V 1 10 23 2 Please connect the controller to user program by using an USB to RS232 cable and SM 4A DB9 RS232 Converter ...

Page 25: ... 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 progra...

Page 26: ...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 tu...

Page 27: ...s 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 from...

Page 28: ...t 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 Please make sure there is no load on the motor shaft before starting the programming The KLS 8080NPS is designed by opto isolated technology We specify 8 30V for power supply pin7 vs pin6 which must be isolated ...

Page 29: ...nverter 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 Bluetooth converter for programming the controller 3 Please download the controller user program from our website for free ...

Page 30: ...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 speed sensor settings Most of PMSM motor with Sin Cosin speed se...

Page 31: ...m 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 user program So output range of Sin Cosin spe...

Page 32: ...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 give a pop up window which show the Write operation is successful Please quit from the user program Please turn off the power supply 6 Please turn on ...

Page 33: ...tem 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 click Write Button and reset the power supply to activate the setting Then the motor will run on the expec...

Page 34: ...he 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 please ...

Page 35: ...able 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 stopped regen 4 This only a...

Page 36: ... 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 damaged or defective Or feed...

Page 37: ...tor Controller User s Manual V 1 10 36 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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