Kelly KLS72501-8080N User Manual
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Kelly KLS72501-8080N User Manual

Sinusoidal brushless motor controller
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Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User's Manual
KLS72501-8080N
KLS96501-8080N
KLS12301-8080N
KLS14401-8080N
KLS72501-8080NPS
KLS96501-8080NPS
KLS12301-8080NPS
KLS14401-8080NPS
Kelly KLS8080N/NPS Motor
Controller User's Manual
KLS72601-8080N
KLS96601-8080N
KLS14201-8080N
KLS72601-8080NPS
KLS96601-8080NPS
KLS14201-8080NPS
KLS72701-8080N
KLS12201-8080N
KLS14301-8080N
KLS72701-8080NPS
KLS12201-8080NPS
KLS14301-8080NPS
V 1.11
Rev.1.10
Feb. 2022

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  • Page 1 Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.11 Kelly KLS8080N/NPS Motor Controller User’s Manual 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 Rev.1.10 Feb. 2022...

  • Page 2: Table Of Contents

    Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.11 Contents Contents ......................1 Chapter 1 Introduction ................... 2 1.1 Overview ................... 2 Chapter 2 Features and Specifications ............3 2.1 General functions ................3 2.2 Features .................... 4 2.3 Specifications ..................5 2.4 Name Regulation ................

  • Page 3: Chapter 1 Introduction

    Chapter 1 Introduction 1.1 Overview This manual introduces the Kelly sinusoidal wave brushless BLDC motor controllers‟ features, their installation and their maintenance. Read the manual carefully and thoroughly before using the controller. If you have any questions, please contact the support center of Kelly Controls.

  • Page 4: Chapter 2 Features And Specifications

    Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.10 alone change the setting in user program or Android App. That is to say, if you want to connect controller to user program or try to do programming, please stop the motor first.

  • Page 5: Features

    Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.10 Brake analog regen mode. This regen mode doesn't need brake switch to support (18) any more. Only available from software version 0106 or advanced version. (19) Enhanced regen brake function. A novel ABS technique provides powerful and smooth regen.

  • Page 6: Specifications

    The name regulation 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.

  • Page 7: Chapter 3 Wiring And Installation

    Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.10 Chapter 3 Wiring and Installation 3.1 Mounting the Controller The controller can be oriented in any position which should be as clean and dry as possible, and if necessary, shielded with a cover to protect it from water and contaminants.

  • Page 8: Connections

    Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.10 3.2 Connections 3.2.1 Pin definition of KLS8080N/NPS Controller 1,The switch signal is valid to 12V on pin11. 2,12V capacity is low.This 12V only can be used for LED or switch signals.
  • Page 9 Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.10 DJ7091Y-2.3-11 Pin Definition (14) REV_SW: Reverse switch input. Orange (6) RTN: Signal return or power supply return. Black (12) FWD: Forward switch or High speed switch White (11) 12V:12V Source Red .
  • Page 10 Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.10 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 Figure 4: KLS8080NPS controller standard wiring...
  • Page 12 Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.10 3.2.3 Optional wiring of KLS8080N/NPS controller The 12V input signal of the pin supplies the second braking function of the controller. Figure 5: Wiring of brake switch(12V): 12V is provided by external source.

  • Page 13: Installation Check List

    Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.10 3.2.4 Communication Port A 4pin connector to RS232 port is provided to communicate with host computer for calibration and configuration. Figure 8: RS232 Interface on 4pin connector to RS232 converter Figure 9：SM-4P connector for communication interface on KLS8080N controller...

  • Page 14: Chapter 4 Programmable Parameters

    Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.10 • Make sure the wire is connected correctly • Turn the PWR switch on. • The fault code will be detected automatically at restart. • With the brake switch open, select a direction and operate the throttle. The motor should spin in the selected direction.

  • Page 15: Step 1

    Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.10 to batteries for Identification Angle operation. Please download the instruction how to use Identification angle function from our website. www.kellycontroller.com/support.php 4.1 Step 1 (1)Low Volt: The min voltage of reporting this fault - Range 18~180 Controller will not operate when battery voltage is near the value so as to protect battery.
  • Page 16 (7)TPS High Err: Hall active pedal, if higher than the value, report the fault of TPS Type. Range: 80~100 As you may know,the output of hall throttle from Kelly is about from 0.86V to 4.2V. Our controller will report 3.3 error code if the output of hall throttle is below 0.5V or above 4.5V by default.
  • Page 17 Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.10 (12)Brake sensor Dead Low: Brake sensor Dead Zone Low. Range: 5~40 Functional description: Set throttle effective starting point Suggestion: Set according to the practical situation, factory default is 20%*5V=1.0V. (13)Brake sensor Dead High: Brake sensor Dead Zone High. Range: 60~95 Functional description: Set throttle effective ending point Suggestion: Set according to the practical situation, factory default is 80%*5V=4.0V.
  • Page 18 Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.10 If throttle got effective output, the controller will report fault and not operate. Suggestion: Set according to the practical situation, factory default is Enable. (20)Brake H-Pedal: Releasing Brake High Pedal Disable...
  • Page 19 Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.10 Suggestion: Set according to the practical situation, factory default is Disable. Configuration Pin Status Running Forward FWD_SW REV_SW Foot Foot Switch Status Switch (12) (14) (15) Neutral Reverse Enable Disable...

  • Page 20: Step 2

    Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.10 function only helps motor stop rolling back too fast. Suggestion: factory default is Disable. (28)Change Direction: If the direction is not what you expected after finish the Identification angle operation, please just choose Change Direction item.

  • Page 21: Step 3

    Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.10 Suggestion: Set according to the practical situation, factory default is 613(3.0V) for Mars 1114/1115/1302/1304 from Motenergy company. Value Range:0-1023 maps 0-5V (7)Line Hall Amplitude: The position signal based on Zero-crossing point. It is only useful when the speed sensor is at 4.
  • Page 22 Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.10 (5)Brake Time: Brake Time, the time of Brake Torque from 0 to max, accuracy 0.1s. Range: 1~250 Factory set is 15 (6)Brake Rls Time: Brake Release Time, the time of Brake Torque from max to 0, accuracy 0.1s.

  • Page 23: How To Use Identification Angle Operation For Kls-8080N Controller

    Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.10 Speed Err Limit:1000 These parameters are used for PID adjustment. If the acceleration is too aggressive, please reduce these three parameters at the same time,vice versa. Please change the Torque Speed Kp every 1000 units,Torque speed Ki every 100 units and Speed Err limit every 500 units.
  • Page 24 Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.10 2, Please connect the controller to user program by using an USB to RS232 cable and SM-4A DB9(RS232) Converter.
  • Page 25 Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.10 Customers also can use a Z-TEK 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 Phone.
  • Page 26 Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.10 Please check whether the Identification Angle item is at 85 or not. It is correct if identification angle item is at 85. 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.
  • Page 27 Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.10 11,As long as it is not reset error code, the value in identification angle will not go back to 85.The value is always at 170.That is to say, the controller is still in the processing of identification operation.

  • Page 28: How To Use Identification Angle Operation For Kls-8080Nps Controller

    Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.10 4.5 How to use Identification angle operation for KLS-8080NPS 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).
  • Page 29 Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.10 Customers also can use a Z-TEK 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 Phone.We don‟t have to use SM-4A to DB9(RS232) converter any more when you use...
  • Page 30 Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.10 www.kellycontroller.com/support.php Please install the user program in your computer, Tablet or Phone. 4.1,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 program in your computer or other devices. Then you may try to click Read button in user program or App.
  • Page 31 Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.10 Usually we just need to configure two parameters in user program according to the specification of Sin/Cosin speed sensor. Please 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 program.
  • Page 32 Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.10 We set the Line hall high err at 972.It is about 4.75V.The line hall low err at 50.It is about 0.25V. So as long as the output is in the range from 0.25V to 4.6V.It should be good. The controller will not report hall error code in this case.
  • Page 33 Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.10 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.

  • Page 34: Chapter 5 Maintenance

    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.

  • Page 35: Buzzer Error Codes

    Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.10 Caution: •Make certain that the motor is connected before trying to run Identification angle The controller needs to be connected to function in the configuration software. batteries, motor and throttle before Identification operation. That is to say, it is not enough to connect only power supply(PWR=pin7) to batteries for Identification Angle operation.
  • Page 36 Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.10 potentiometers or incorrect wiring. 3. Controller is damaged. Contact Kelly about a warranty repair. Over temperature ¤¤ ¤¤¤ The controller temperature has exceeded 100℃. The controller will be stopped but will restart when temperature falls below 80℃.

  • Page 37: Contact Us

    Kelly KLS8080N/NPS Sinusoidal Brushless Motor Controller User’s Manual V 1.10 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...

This manual is also suitable for:

Kls72601-8080nKls72701-8080nKls96501-8080nKls96601-8080nKls12201-8080nKls12301-8080n ... Show all

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