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Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual
Kelly KLS-8080N/NPS/NA
Model（-8080N/NPS/NA）:
KLS72501
KLS72121
KLS84501
KLS84121
KLS96401
KLS96111
KLS12401
KLS12111
KLS14351
KLS14101
KLS16401
*Model: For ease of reading, the suffix "-8080N/NPS" after the model name has been omitted.
High-current Opto-isolated Motor Controllers
User Manual
Devices Supported:
KLS72601
KLS84601
KLS96501
KLS12501
KLS14401
KLS16601
KLS72701
KLS84701
KLS96601
KLS12601
KLS14551
KLS16751
KLS72801
KLS84901
KLS96701
KLS12701
KLS14601
KLS16901
V2.1.0
KLS72101
KLS84111
KLS96901
KLS12901
KLS14751
Rev. 2.1.0
Sep. 2024
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Summary of Contents for Kelly KLS-8080N/NPS/NA Series
- Page 1 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 Kelly KLS-8080N/NPS/NA High-current Opto-isolated Motor Controllers User Manual Devices Supported: Model（-8080N/NPS/NA）: KLS72501 KLS72601 KLS72701 KLS72801 KLS72101 KLS72121 KLS84501 KLS84601 KLS84701 KLS84901 KLS84111 KLS84121 KLS96401 KLS96501 KLS96601 KLS96701 KLS96901 KLS96111 KLS12401...
- Page 2 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 Contents Chapter 1 Introduction ................2 1.1 Overview........................ 2 Chapter 2 Features and Specifications ............ 2.1 General functions ....................3 2.2 Features ........................ 4 2.3 Specifications ......................5 2.4 Name Regulation ....................5 Chapter 3 Wiring and Installation .............
- Page 3 1.1 Overview KLS-N is a waterproof controller with a protection rating of IP66. This manual introduces the features, installation, and maintenance of the Kelly sinusoidal brushless DC (BLDC) motor controller. Please read the manual carefully before using the controller. If you have any questions, contact the Kelly Controls support center.
- Page 4 8. The controller can be programmed and configured using user program or an Android app. For the PC side, please connect the controller and PC using a Kelly USB cable or a USB-RS232 set to use the user program. For the Android side, please connect the controller to a Bluetooth adapter which purchased from out site to use the configuration app on Android devices.
- Page 5 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 22. CAN Bus (Optional), broadcast type, with a customizable baud rate(default at 250Khz) . CAN bus is not included by default in KLS-N controllers. 23. Bidirectional anti-slip function (Optional), Prevent the stationary vehicle moving in the opposite direction.
- Page 6 The name regulation of Kelly BLDC motor controllers KLS72501-8080N/NPS For example: : Kelly BLDC motor controller based on sinusoidal waveform which is supposed to work with BLDC motor with three hall sensors. All KLS controllers can do regen brake function by default.
- Page 7 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 Kelly KLS-8080N/NPS Sinusoidal Brushless Motor Controller Model 60 seconds Continuous Battery Max Operating Cooling (8080N/NPS/NA) Current Current Voltage Voltage Type* KLS72501 500A 200A 24-72V KLS72501 500A 300A 24-72V KLS72601 600A...
- Page 8 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 115V KLS96111 1100AA 440A 24-96V 115V KLS96111 1100A 660A 24-96V 140V KLS12401 400A 160A 24-120V 140V KLS12401 240A 24-120V 140V KLS12501 500A 200A 24-120V 140V KLS12501 500A 300A 24-120V 140V...
- Page 9 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 Chapter 3 Wiring and Installation 3.1 Mounting the Controller The controller can be placed anywhere but should be kept as clean and dry as possible. If necessary, covering with a cover to prevent water and contaminants from entering.
- Page 10 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 Figure 1: With Aluminum Heatsink at the bottom mounting holes’ dimensions (dimensions in millimeters) +/B+/B-/U/V/W:M8...
- Page 11 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 Figure 2: With Aluminum Liquid Cooling Heatsink at the bottom mounting holes’ dimensions (dimensions in millimeters) +/B+/B-/U/V/W:M8...
- Page 12 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 Figure3: With Sealed Aluminium Housing mounting holes’ dimensions (dimensions in millimeters) +/B+/B-/U/V/W:M8...
- Page 13 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 Figure4: With Sealed Aluminium Housing And Aluminum Liquid Cooling Heatsink at the bottom mounting holes’ dimensions (dimensions in millimeters) +/B+/B-/U/V/W:M8...
- Page 14 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 3.2 Connections 3.2.1 Pin definition of KLS-N Controller waterproof connector Figure 10: DJ7091Y-2.3-11 Pin Definition 1. REV_SW(14): Reverse switch input. ※Orange 2. GND(6): Signal return or power supply return. ※Black 3.
- Page 15 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 2. Throttle(3): Throttle analog input, 0-5V. ※ Green 3. GND(20): Signal return. ※Black 4. Meter(8): Copied signal of hall-A sensor. ※Dark Gray 5. 5V(4): 5V Supply, <40mA. ※Purple Brake_AN(2): Brake variable regen or Boost function. ※Brown 12V(11): 12V Supply.
- Page 16 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 3.2.2 KLS-N Controller Standard Wiring Figure 5: KLS-8080I/N controller standard wiring (Battery is also used as controller’s power supply)
- Page 17 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 Figure 6: KLS8080I/NPS controller standard wiring (Battery is also used as controller’s power supply) Caution! Make sure the controller wiring is correct and has been double checked, especially the B+ and the B- of the controller before power on. Wiring faults will damage the controller.
- Page 18 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 Figure 12: SM-4P connector 3.3 Installation Check List 1. Conduct a visual inspection to ensure that components such as mounting holes, wiring, and sealing rings are intact. 2. Check the connection between the battery B+ and NC. For controllers without a fuse, check the connection between the battery B+ and the controller B+ instead of NC.
- Page 19 3. Use the RS232-USB cable and SM-4P adapter provided by Kelly to connect to a host computer. During the opeartion, the PWR of the controller needs to be provided with >+18V (for a 24V controller, provide >+8V).
- Page 20 You have three way to connect the controller to host computers or Android devices: 1. Using Kelly USB cable, connect SM-4P(Female) from controller to the USB port on computer. You may download Kelly USB Cable driver or at our website.
- Page 21 11). Please make sure there is no load on the motor shaft before starting the programming. 2. Connect the controller to PC by using a Kelly USB cable or an USB to RS232 set. For Android devices, please use the Bluetooth adapter to connect the controller.
- Page 22 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 6. Turn on the power supply after the power supply is off for a few seconds. The motor shaft will try to run on random directions. This is a normal operating phenomenon.
- Page 23 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 In order to protect the battery, if the battery voltage is high1er Configuration than this value, the controller will not work. Hall 0-1000 Hall Galvanometer Rate(A). Default PhaseCurr Max 409-2048 The Max AD value of phase current.
- Page 24 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 2:0-5V, hall active pedal regen. Brake Dead Zone Lower Limit, User Brake Dead Low 5-40% 20%*5V=1V. Configuration Brake Dead Zone Upper Limit, User Brake Dead High 60-95% 80%*5V=4V. Configuration User...
- Page 25 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 value will accelerate the response speed but will increase high-speed jitter; decreasing this value will reduce high-speed jitter but will also decrease the response speed. Ki of D-ring, the integral gain in D-ring current loop, is mainly effective at speeds below 400 RPM.
- Page 26 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 Torque mode Brake Time, User Brake Time 1-250 the time of Brake Torque from 0 to max,(X0.1second) Configuration Torque mode Brake release Time, User Brake Rls Time 1-250 the time of Brake Torque from max to 0,(X0.1second) Configuration Switch regen ‘s regen strength.
- Page 27 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 Configuration Minimum excitation coefficient (A) This value affects the current and maximum speed of the motor when the field weakening function is enabled. User Min Excitation 0-100 When this value = 0, the field weakening function has no...
- Page 28 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 Available for sine/cosine sensor 0° Hall value Hall sensor sequence value at motor electrical angle 0°. Auto 60° Hall value Hall sensor sequence value at motor electrical angle 60° Auto 120°Hall value...
- Page 29 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 Boost function, Checked: enable boost switch, checked/ Connect Brake_AN (PIN2) to 12V to start boost. User Boost unchecked unchecked Unchecked: Connect Brake_AN (PIN2) to 12V to start switch Configuration regen.
- Page 30 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 Chapter 5 Maintenance Caution! There are no user-serviceable parts inside the controller. Do not attempt to open the controller on your own, as this will void your warranty. The exterior of the controller should be cleaned periodically.
- Page 31 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 recharge. When the battery voltage continuously exceeds the low voltage cut-off value for 5 seconds, the controller will resume normal operation. The controller did not receive CAN Resend CAN commands from VCU.
- Page 32 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 error 2. Motor rotation speed is above 50RPM. Reserved 4, 2 ¤¤¤¤ ¤¤ May occur after motor temp being set to 1 or 2. Motor The Motor temperature has exceeded the configured 4, 3 ¤¤¤¤...
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