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Kelly KLS-180N User Manual

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Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User's Manual V1.11
Kelly KLS-8080N/NPS KLS-180N/NPS
Motor Controller User's Manual
Devices Supported:
KLS72501-8080N
KLS72601-8080N
KLS72701-8080N
KLS96301-8080N
KLS96401-8080N
KLS96501-8080N
KLS96601-8080N
KLS12201-8080N
KLS12301-8080N
KLS12401-8080N
KLS14201-8080N
KLS14301-8080N
KLS14401-8080N
KLS12501-180N
KLS12601-180N
KLS14501-180N
KLS14601-180N
KLS18501-180N
KLS18601-180N
KLS72501-8080NPS
KLS72601-8080NPS
KLS72701-8080NPS
KLS96301-8080NPS
KLS96401-8080NPS
KLS96501-8080NPS
KLS96601-8080NPS
KLS12201-8080NPS
KLS12301-8080NPS
KLS12401-8080NPS
KLS14201-8080NPS
KLS14301-8080NPS
KLS14401-8080NPS
KLS12501-180NPS
KLS12601-180NPS
KLS14501-180NPS
KLS14601-180NPS
KLS18501-180NPS
KLS18601-180NPS
Rev.1.11
Nov. 2022

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  • Page 1 Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 Kelly KLS-8080N/NPS KLS-180N/NPS Motor Controller User’s Manual Devices Supported: KLS72501-8080N KLS72501-8080NPS KLS72601-8080N KLS72601-8080NPS KLS72701-8080N KLS72701-8080NPS KLS96301-8080N KLS96301-8080NPS KLS96401-8080N KLS96401-8080NPS KLS96501-8080N KLS96501-8080NPS KLS96601-8080N KLS96601-8080NPS KLS12201-8080N KLS12201-8080NPS KLS12301-8080N KLS12301-8080NPS KLS12401-8080N KLS12401-8080NPS KLS14201-8080N KLS14201-8080NPS...

  • Page 2: Table Of Contents

    4.1 Step 1 ........................18 4.2 Step 2 ........................23 4.3 Step 3 ........................24 4.4 How to use Identification angle operation for KLS-8080N and KLS-180N controller ..........................26 4.5 How to use Identification angle operation for KLS-8080NPS and KLS-180NPS controller ........................

  • Page 3: Chapter 1 Introduction

    We specify 8-30V for power supply which must be isolated from main battery pack B+/B-.You may use an isolated DCDC converter or a separate 12V battery for power supply.KLS-8080N and KLS-180N are supposed to work with BLDC motor with hall sensors. KLS-8080NPS and KLS-180NPS can work with brushless motor with Sin/Cosin speed sensors.

  • Page 4: Chapter 2 Features And Specifications

    Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 Anyway please try to do identification angle operation before running the motor. And please don't try to connect the controller to user program while the motor is still running, let 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 KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 (15) Optional joystick throttle. A bi-symmetrical 0-5V signal for both forward and reversing. (16) Configurable motor over-temperature detection and protection with the recommended thermistor KTY84-130/150 or KTY83-122. (17) 3 hall position sensor inputs. Open collector, pull up provided. Sin/Cosin Speed sensors inputs.

  • Page 6: Specifications

    Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 17) Configurable high pedal protection: the controller will not work if high throttle is detected at power on. 18) Current multiplication: Take less current from battery, output more current to motor.

  • Page 7: Name Regulation

    The name regulation of Kelly KLS motor controllers KLS: Kelly BLDC motor controller based on sinusoidal waveform. KLS-8080N and KLS-180N are supposed to work with brushless motor with three hall sensors while KLS-8080NPS and KLS-180NPS 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 8: Chapter 3 Wiring And Installation

    Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 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 9 Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 mounting holes‟ dimensions Figure2: KLSxx301-8080N/NPS (dimensions in millimeters) +/B+/B-/U/V/W:M8...
  • Page 10 Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 Figure3: KLSxx401-8080N/NPS KLSxx501-8080N/NPS KLSxx601-8080N/NPS KLSxx701-8080N/NPS mounting holes‟ dimensions (dimensions in millimeters) +/B+/B-/U/V/W:M8...
  • Page 11 Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 Figure4: KLS-180N/NPS mounting holes‟ dimensions (dimensions in millimeters) +/B+/B-/U/V/W:M8...

  • Page 12: Connections

    Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 3.2 Connections 3.2.1 Pin definition 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. 3,Boost and Brake analog regeneration mode used the same pin as pin2.
  • Page 13 Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 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 14 Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 3.2.2 Standard Wiring Figure 5: KLS-8080N KLS-180N controller standard wiring...
  • Page 15 Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 Figure 6: KLS8080NPS KLS180NPS controller standard wiring...
  • Page 16 The 12V input signal of 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 or KLS-180N controller on pin11 Figure 9: Wiring diagram for motor temperature sensor NOTE: KLS controller can support KTY84-150, KTY84-130,KTY83-122 thermistors.

  • Page 17: Installation Check List

    Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 3.2.4 Communication Port A 4pin connector to RS232 port is provided to communicate with host computer for calibration and configuration. Figure 10: RS232 Interface on 4pin connector to RS232 converter Figure 11：SM-4P connector for communication interface on KLS8080N controller 3.3 Installation Check List...

  • Page 18: Chapter 4 Programmable Parameters

    Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 • 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 19: Step 1

    Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 4.1 Step 1 (1)Low Volt: The min voltage of reporting this fault - Range 18~173, depending on model. Controller will not operate when battery voltage is near the value so as to protect battery.
  • Page 20 (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 21 Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 (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 22 Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 Value range: Enable and Disable Functional description: If enabled, the controller will detect the current pedal status at power up. If throttle got effective output, the controller will report fault and not operate.
  • Page 23 Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 (20-B)Foot Switch Value range: Enable and Disable Functional description: If enabled, the foot switch will be activated. The controller will not accept the throttle signal if the foot switch is turned off. Please see figure 4.1.

  • Page 24: Step 2

    Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 control quit. Suggestion: factory default is Disable. (27)Anti-Slip: If enabled, the controller will try to prevent the vehicle rolling back on downhill faster and faster. If the ratio of gearbox is high, it can try to help the motor stop on the downhill. But usually this function only helps motor stop rolling back too fast.

  • Page 25: Step 3

    Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 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 will resume work when the motor temp is at 110 degrees inside. Range: 60~170 (6)Line Hall Zero: It is only useful when the speed sensor is at 4.
  • Page 26 Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 Factory set is 0 (3)Accel Time: Accel Time, the time of TPS Torque from 0 to max, accuracy 0.1s, 5 is equal to 0.5s. Range: 1~250 Factory set is 10 (4)Accel Rls Time: Accel Release Time, the time of TPS Torque from max to 0, accuracy 0.1s.

  • Page 27: How To Use Identification Angle Operation For Kls-8080N And Kls-180N Controller

    KLS-8080N controller is designed for BLDC motor with three hall sensors. By default, the speed sensor type is set at 2 from factory setting for KLS-8080N and KLS-180N controller. 1,Please hook up the controller for identification angle operation according to the wiring diagram below.
  • Page 28 Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 2, Please connect the controller to user program by using an USB to RS232 cable and SM-4A DB9(RS232) Converter.
  • Page 29 Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 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 30 Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 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 31 Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 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 32: How To Use Identification Angle Operation For Kls-8080Nps And Kls-180Nps

    Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 4.5 How to use Identification angle operation for KLS-8080NPS and KLS-180NPS 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 33 Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 2,Please connect the controller to user program by using an USB to RS232 cable and SM-4A DB9(RS232) Converter. 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.
  • Page 34 Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 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. 4.1,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.
  • Page 35 Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 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 36 Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 So output range of Sin/Cosin speed sensor is 3-1.1V=1.9V to 3+1.1V=4.1V.(1.9V-4.1V). 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.
  • Page 37 Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 see any error codes. 13,If the constant beep sound lasts above 5 minters and there are other error codes such as Identify error, hall err etc, please return to the first picture of user program. Please write 85 instead in identification angle by manual.

  • Page 38: 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 39: Buzzer Error Codes

    Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 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 40 Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 caused by too low a value of Regen or throttle 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 41: Contact Us

    Kelly KLS-8080N/NPS KLS-180N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.11 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:

Kls-8080npsKls-8080nKls-180npsKls72501-8080nKls72501-8080npsKls72601-8080n ... Show all

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