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Kelly KLS-8080N Series User Manual

High-current opto-isolated motor controllers
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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
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
KLS14501
KLS16751
KLS72801
KLS84901
KLS96701
KLS12701
KLS14601
KLS16901
V2.1.0
KLS72121
KLS84111
KLS96901
KLS12901
KLS14751
Rev. 2.1.0
Sep. 2024

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Summary of Contents for Kelly KLS-8080N 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 KLS72121 KLS84501 KLS84601 KLS84701 KLS84901 KLS84111 KLS84121 KLS96401 KLS96501 KLS96601 KLS96701 KLS96901 KLS96111 KLS12401 KLS12501...
  • 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 140V KLS12501 500A 200A 24-120V 140V KLS12501 500A 300A 24-120V 140V KLS12601 600A 240A 24-120V 140V KLS12601 600A 360A 24-120V 140V KLS12701 700A 280A 24-120V 140V KLS12701 700A 420A 24-120V...
  • 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 1. Connect the controller and the motor according to the standard wiring diagram (Figure 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.
  • Page 21 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 For Android devices, please use the Bluetooth adapter to connect the controller. 3. Download the corresponding USB drivers and the user program from our website, only one driver can be installed, two drivers installed at same time are incompatible. After the USB driver is successfully installed, please restart your PC.
  • Page 22 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 10. Connect the controller to user program. You will see 85 in the Identification_Angle. Means, the controller auto-identification operation is successful. The motor is ready to run. 11. If Identification_Angle value is 170, it means that auto-identification is still in progress.
  • Page 23 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 Software Version Software Version. Default Controller Volt 0-144 Controller Voltage(V). Default Minimum normal voltage(V), User Low Volt 18-180 In order to protect the battery, if the battery voltage is lower Configuration than this value, the controller will not work.
  • Page 24 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 throttle midpoint, to adjust throttle response amplitude. Configuration When moving backward , the MAP value corresponding to User TPS Rev MAP 0-100% throttle midpoint , to adjust throttle response amplitude.
  • Page 25 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 effective at speeds below 400 RPM. Increasing this value will Configuration improve current accuracy but will increase startup jitter and instability. Decreasing this value will enhance stability and reduce startup jitter but will also lower current accuracy.
  • Page 26 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 Neutral gear regen ‘s regen strength, User NTL Brk 0-50% 0= no regen. Configuration Torque mode accelerate Time, User Accel Time 1-250 the time of torque from 0 to max,(X0.1second)
  • Page 27 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 Sensor Type: Hall sensor Speed Sensor User 2 /3/ 4 Type Magnetic encoder. Configuration Linear Hall sensor（sine/cosine sensors） User Resolver Poles 2-32 Reserved. Configuration Minimum excitation coefficient (A) This value affects the current and maximum speed of the motor when the field weakening function is enabled.
  • Page 28 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 Phase 0: disabled 1: enabled, 255: error. Available for sine/cosine sensor Synchro Initial Angle , defines the reference point of the Synchro Initial 0-65535 8192 position when sensor type is set to 4.
  • Page 29 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 2.5V-5V: backward. Has same range of dead zone as TPS dead zone. Three-gear function Three Gears checked/ Check: Enable three operating gears: User unchecked Switch unchecked Forward, Neutral, Reverse. Configuration Uncheck: Forward only.
  • Page 30 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 Source of Value *: 1. User : Users should modify these values to adjust the controller. 2. Auto: These values are generated by the sensor or the controller's program, and users can affect the operation of the controller by modifying these values.
  • Page 31 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 1. Battery voltage is too high for the controller. Check battery volts and controller configuration. Over voltage error 2. Regeneration over-voltage. Controller will limit regen or 1, 2 ¤ ¤¤...
  • Page 32 Kelly KLS-8080N/NPS/NA Series Sinusoidal BLDC Motor Controller User Manual V2.1.0 1. Speed sensor type error,customers may set the correct sensor type through user program or App. Angle sensor 2. Incorrect wiring. 3, 4 ¤¤¤ ¤¤¤¤ error 3. Speed sensor is damaged or defective. Or feedback signal is erratic.

This manual is also suitable for:

Kls-8080nps seriesKls-8080na seriesKls72501-8080nKls72601-8080nKls72701-8080nKls72801-8080n ... Show all