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Kelly KLS14801-8080N, User Manual

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Page: 11 / 43

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

’s Manual

V1.13

10

Figure 1: With Aluminum Heatsink at the bottom

mounting holes

‟ dimensions

(dimensions in millimeters) +/B+/B-/U/V/W:M8

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Summary of Contents for KLS14801-8080N

Page 1: ...KLS11401 8080NPS KLS72801 8080N KLS11501 8080N KLS72801 8080NPS KLS11501 8080NPS KLS72101 8080N KLS11601 8080N KLS72101 8080NPS KLS11601 8080NPS KLS84501 8080N KLS14351 8080N KLS84501 8080NPS KLS1435...

Page 2: ...Wiring and Installation 9 3 1 Mounting the Controller 9 3 2 Connections 13 3 3 Installation Check List 18 Chapter 4 Programmable Parameters 19 4 1 Step 1 20 4 2 Step 2 25 4 3 Step 3 26 4 4 How to use...

Page 3: ...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 4: ...tage 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 all...

Page 5: ...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 6: ...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 7: ...ed on sinusoidal waveform KLS 8080N is supposed to work with brushless motor with three hall sensors while KLS 8080NPS can work with Sin Cosin speed sensors There are 5V Sin Cosin and GND I O ports fo...

Page 8: ...6 A KLS72801 8080N NPS 800 480 24 72 86 B KLS72101 8080N NPS 1000 400 24 72 86 A KLS72101 8080N NPS 1000 600 24 72 86 B KLS84601 8080N NPS 600 240 24 84 100 A KLS84601 8080N NPS 600 360 24 84 100 B KL...

Page 9: ...NPS 400 240 24 144 173 B KLS14451 8080N NPS 450 180 24 144 173 A KLS14451 8080N NPS 450 270 24 144 173 B KLS14601 8080N NPS 600 240 24 144 173 A KLS14601 8080N NPS 600 360 24 144 173 B KLS14801 8080N...

Page 10: ...ed with a cover to protect it from water and 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...

Page 11: ...Kelly KLS 8080N NPS Sinusoidal BLDC PMSM Controller User s Manual V1 13 10 Figure 1 With Aluminum Heatsink at the bottom mounting holes dimensions dimensions in millimeters B B U V W M8...

Page 12: ...Kelly KLS 8080N NPS Sinusoidal BLDC PMSM Controller User s Manual V1 13 11 Figure 2 With Aluminum Liquid Cooling Heatsink at the bottom mounting holes dimensions dimensions in millimeters B B U V W M8...

Page 13: ...Kelly KLS 8080N NPS Sinusoidal BLDC PMSM Controller User s Manual V1 13 12 Figure3 With Sealed Aluminium Housing mounting holes dimensions dimensions in millimeters B B U V W M8...

Page 14: ...s low 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...

Page 15: ...N Signal return Black 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...

Page 16: ...Kelly KLS 8080N NPS Sinusoidal BLDC PMSM Controller User s Manual V1 13 15 at switch on 3 2 2 Standard Wiring Figure 5 KLS 8080N controller standard wiring...

Page 17: ...Kelly KLS 8080N NPS Sinusoidal BLDC PMSM Controller User s Manual V1 13 16 Figure 6 KLS8080NPS controller standard wiring...

Page 18: ...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 19: ...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 20: ...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 21: ...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 22: ...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 23: ...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 24: ...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 25: ...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 26: ...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 27: ...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 28: ...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 29: ...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 30: ...Kelly KLS 8080N NPS Sinusoidal BLDC PMSM Controller User s Manual V1 13 29 2 Please connect the controller to user program by using an USB to RS232 cable and SM 4A DB9 RS232 Converter...

Page 31: ...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 32: ...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 33: ...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 34: ...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 35: ...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 36: ...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 37: ...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 38: ...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 39: ...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 40: ...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 41: ...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 42: ...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 43: ...Controller User s Manual V1 13 42 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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