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

’s Manual 

                V1.13

 

                                                                                                                                         

 

6

 

2.4 Name Regulation 

The name regulation of Kelly KLS motor controllers

 

KLS: Kelly BLDC motor controller based 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 for 
brushless motor with Sin/Cosin speed sensors. 
KLS-8080N is designed by opto-isolated technology. We specify 8-20V for power supply 
which must be isolated from main battery pack B+/B-. 

 

Kelly KLS-8080N/NPS Sinusoidal Brushless Motor Controller

 

Model 

60 seconds   

Current 

(Amp) 

Continuous 

Current 

(Amp) 

Battery   

Voltage 

(Volt) 

Max 

Operating 

Voltage(Volt) 

Cooling 

Type 

(see note) 

KLS72501-8080N/NPS 

500 

200 

24-72 

86 

KLS72501-8080N/NPS 

500 

250 

24-72 

86 

KLS72601-8080N/NPS 

600 

240 

24-72 

86 

KLS72601-8080N/NPS 

600 

300 

24-72 

86 

KLS72701-8080N/NPS 

700 

280 

24-72 

86 

KLS72701-8080N/NPS 

700 

350 

24-72 

86 

KLS96401-8080N/NPS 

400 

160 

24-96 

115 

KLS96401-8080N/NPS 

400 

200 

24-96 

115 

KLS96501-8080N/NPS 

500 

200 

24-96 

115 

KLS96501-8080N/NPS 

500 

250 

24-96 

115 

KLS96601-8080N/NPS 

600 

300 

24-96 

115 

KLS11401-8080N/NPS 

400 

160 

24-110 

132 

KLS11401-8080N/NPS 

400 

240 

24-110 

132 

KLS11501-8080N/NPS 

500 

200 

24-110 

132 

KLS11501-8080N/NPS 

500 

300 

24-110 

132 

KLS14351-8080N/NPS 

350 

140 

24-144 

173 

KLS14351-8080N/NPS 

350 

210 

24-144 

173 

KLS14401-8080N/NPS 

400 

160 

24-144 

173 

KLS14401-8080N/NPS 

400 

240 

24-144 

173 

KLS14451-8080N/NPS 

450 

180 

24-144 

173 

KLS14451-8080N/NPS 

450 

270 

24-144 

173 

Note: There are two types of cooling heatsink. 
A: Aluminum Heatsink      B: Aluminum Liquid Cooling Heatsink 

Содержание KLS11401-8080N

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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