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Kelly KLS8080I/IPS Sinusoidal Brushless Motor Controller User’s Manual

V 1.11

Kelly KLS8080I/IPS Motor

Controller User’s Manual

Rev.1.11

Dec.2017

KLS72501-8080I

KLS72601-8080I

KLS72701-8080I

KLS96501-8080I

KLS96601-8080I

KLS12201-8080I

KLS12301-8080I

KLS14201-8080I

KLS14301-8080I

KLS14401-8080I

KLS72501-8080IPS

KLS72601-8080IPS

KLS72701-8080IPS

KLS96501-8080IPS

KLS96601-8080IPS

KLS12201-8080IPS

KLS12301-8080IPS

KLS14201-8080IPS

KLS14301-8080IPS

KLS14401-8080IPS

Summary of Contents for KLS8080I/IPS

Page 1: ...1 11 Dec 2017 KLS72501 8080I KLS72601 8080I KLS72701 8080I KLS96501 8080I KLS96601 8080I KLS12201 8080I KLS12301 8080I KLS14201 8080I KLS14301 8080I KLS14401 8080I KLS72501 8080IPS KLS72601 8080IPS KLS72701 8080IPS KLS96501 8080IPS KLS96601 8080IPS KLS12201 8080IPS KLS12301 8080IPS KLS14201 8080IPS KLS14301 8080IPS KLS14401 8080IPS ...

Page 2: ...on 5 Chapter 3 Wiring and Installation 6 3 1 Mounting the Controller 6 3 2 Connections 8 3 3 Installation Check List 13 Chapter 4 Programmable Parameters 14 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 8080I controller 22 4 5 How to use Identification angle operation for KLS 8080IPS controller 25 Chapter 5 Maintenance 31 5 1 Cleaning 32 5 2 Config...

Page 3: ...ushless motor It uses high power 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 choic...

Page 4: ...olt output to supply various kinds of hall sensors 10 5 switch inputs which are activated by connection to 12V Default to throttle switch brake switch reversing switch forward switch and Boost switch 11 3 analog 0 5V inputs that default to throttle input Brake analog input and motor temperature input 12 Copy signal of one of sensors 13 Configurable boost switch Enables the maximum output power ach...

Page 5: ...otection 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 connectors for small signal 15 Thermal protection current cut back warning and shutdown on high temperature 16 Controller can do auto_Identification angle for different Sine Cosi...

Page 6: ...on of Kelly KLS motor controllers KLS 8080I IPS KLS Kelly BLDC motor controller based on sinusoidal waveform KLS8080I is supposed to work with brushless motor with three hall sensors while KLS8080IPS 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 KLS8080I is designed by opto isolated technology We specify 8 30V for ...

Page 7: ...oller 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 Figure 1 Figure 1 KLS72501 8080I IPS KLS12201 8080I I...

Page 8: ...Motor Controller User s Manual V 1 10 7 Figure2 KLS72601 8080I IPS KLS72701 8080I IPS KLS96501 8080I IPS KLS96601 8080I IPS KLS1 4401 8080I IPS mounting holes dimensions dimensions in millimeters Size 288mm 186mm 268mm 159mm 81mm B B U V W M8 ...

Page 9: ...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 KLS8080I IPS waterproo...

Page 10: ... 2 3 21 Pin Definition 21 RTN Signal return Black 5 5V 5V supply output 40mA Purple 18 Hall A Hall phase A Yellow This is Sine signal input on KLS8080IPS 17 Hall B Hall phase B Dark Green This is Cosine signal input on KLS8080IPS 16 Hall C Hall phase C Dark Blue There is no hall C signal input on KLS8080IPS Notes 1 All RTN pins are internally connected 2 Meter function is to copy either of hall se...

Page 11: ...Kelly KLS8080I IPS Sinusoidal Brushless Motor Controller User s Manual V 1 10 10 3 2 2 Standard Wiring of KLS8080I IPS Controller Figure 3 KLS8080I controller standard wiring ...

Page 12: ...Kelly KLS8080I IPS Sinusoidal Brushless Motor Controller User s Manual V 1 10 11 Figure 4 KLS8080IPS controller standard wiring ...

Page 13: ...ntroller Figure 5 Wiring of brake switch 12V 12V is provided by external source Figure 6 Wiring of brake switch 12V 12V is provided by KLS8080I controller on pin11 Figure 7 Wiring diagram for motor temperature sensor NOTE The motor temperature sensor and brake switch used the same I O port on pin1 Both functions can not be used at the same time KLS controller can support KTY84 150 and KTY84 130 th...

Page 14: ...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 15: ...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 16: ...72V 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...

Page 17: ...ou can 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 t...

Page 18: ...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 supposed to enabl...

Page 19: ...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 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...

Page 20: ... 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 Suggestion Set a...

Page 21: ...ease inquire the KLS 8080IPS model before ordering 4 Resolver Poles Resolver Poles The pair pole number 2 Range 2 32 It is only used for the Resolver sensor type 5 Motor Temp Sensor Motor Temp Sensor 0 None 1 KTY84 130 or 150 2 KTY83 122 Range 0 2 High Temp Cut Out C Motor High Temp Cut Out nominal value 130 C Range 60 170 Resume C Motor High Temp Resume Temp nominal value 110 C The controller wil...

Page 22: ...used to adjust the regen current of releasing throttle regen mode type The regen will happen as long as the throttle is released completely Factory set is 0 2 NTL Brk NTL Braking Percent the percent of Neutral Braking in max braking Range 0 50 Only useful when you enable Three gears switch in user program The regen will happen when you turn F N R switch from Forward or backward to Neutral position...

Page 23: ... will help the motor change the direction of motor quickly after you shift throttle from 0V to 5V or from 5V to 0V Suggestion factory default is Disable 11 IVT BRK MAX and IVT BRK MIN These two items are only useful when Joystick function is enabled in the user program When you want to use Change Dir Brake to reduce the delay time when you shift the direction under joystick operation there is a RP...

Page 24: ...no load on the motor shaft before starting the programming The KLS 8080I is designed by opto isolated technology We specify 8 30V for power supply pin7 vs pin6 which must be isolated from main battery pack B B Usually customers can use 12V car battery or 12V Isolated type DCDC converter for this purpose 2 Please connect the controller to user program by using an USB to RS232 cable and SM 4A DB9 RS...

Page 25: ...r 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 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...

Page 26: ...lease turn on the power supply after the power supply is off for a few seconds The beeper will send a constant beep after the power supply is turned on The motor shaft will try 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 constant beep sound will be d...

Page 27: ... instead in identification angle by manual If there are no any error codes 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 ...

Page 28: ...t the speed sensor type is set at 4 from factory setting for KLS 8080IPS 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 8080IPS 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 8080IPS 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: ...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 the power supp...

Page 33: ... 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 expected...

Page 34: ...fect the Identification angle operation Please try to eliminate the error codes before Identification angle operation Use a straight through RS232 cable or USB converter provided by Kelly to connect to a host computer Provide 18V to PWR for a 24V controller provide 8V Wire power supply return supply negative to any RTN pin KLS controller requires a 4pin connector to Kelly RS232 Converter to suppor...

Page 35: ...seconds if battery volts returns to normal 2 Check battery volts recharge if required 1 4 Reserved 2 1 Motor did not start Motor did not reach 25 electrical RPM within 2 seconds of start up Hall sensor or phase wiring problem 2 2 Internal volts fault 1 Measure that B PWR are correct when measured to B or RTN 2 There may be excessive load on the 5V supply caused by too low a value of Regen or throt...

Page 36: ...ation function instruction from our website 2 Incorrect wiring 3 Speed sensor is damaged or defective Or feedback signal is erratic 4 1 Reserved 4 2 Reserved 4 3 Motor over temperature Motor temperature has exceeded the configured maximum The controller will shut down until the motor temperature cools down 4 4 Hall Galvanometer sensor error 1 Hall galvanometer device is damaged inside the controll...

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