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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 KLS72501-8080N

Page 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 KLS...

Page 2: ...hapter 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...

Page 3: ...o 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 qu...

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 standar...

Page 5: ...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...

Page 6: ...n 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 c...

Page 7: ...ants 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 sur...

Page 8: ...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 varia...

Page 9: ...ack 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 Cosin...

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: ...l 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 KLS808...

Page 13: ...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...

Page 14: ...e 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...

Page 15: ...ontroller 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 18 136 144...

Page 16: ...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 thro...

Page 17: ...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...

Page 18: ...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 throttl...

Page 19: ...nalog 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...

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...

Page 21: ...ly 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 val...

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...

Page 23: ...tification 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...

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...

Page 26: ...o 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 w...

Page 27: ...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 Otherwi...

Page 28: ...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...

Page 29: ...verter 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 c...

Page 30: ...ead 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...

Page 31: ...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...

Page 32: ...e 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 ple...

Page 33: ...em 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 aga...

Page 34: ...e 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 thr...

Page 35: ...ble 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...

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 se...

Page 37: ...or 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 Sal...

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