Kelly KLS11401-8080N User manual

Kelly KLS-8080N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.13
Kelly KLS-8080N/NPS
Motor Controllers
User’s Manual
Devices Supported:
KLS72501-8080N
KLS72501-8080NPS
KLS72601-8080N
KLS72601-8080NPS
KLS72701-8080N
KLS72701-8080NPS
KLS96401-8080N
KLS96401-8080NPS
KLS96501-8080N
KLS96501-8080NPS
KLS96601-8080N
KLS96601-8080NPS
KLS11401-8080N
KLS11401-8080NPS
KLS11501-8080N
KLS11501-8080NPS
KLS14351-8080N
KLS14351-8080NPS
KLS14401-8080N
KLS14401-8080NPS
KLS14451-8080N
KLS14451-8080NPS
Rev.1.13

Kelly KLS-8080N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.13
Feb. 2023

Kelly KLS-8080N/NPS Sinusoidal BLDC/PMSM Controller User’s Manual V1.13
1
Contents
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................................................................................................... 6
Chapter 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 Identification angle operation for KLS-8080N controller.................... 25
4.5 How to use Identification angle operation for KLS-8080NPS controller............... 30
Chapter 5 Maintenance............................................................................. 36
5.1 Cleaning .............................................................................................................. 36
5.2 Configuration....................................................................................................... 36
Table 1: ERROR CODES............................................................................ 37
Buzzer Error Codes................................................................................................... 37
Contact Us: ................................................................................................ 39

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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.
Kelly‟s programmable motor controllers provide efficient, smooth and quiet controls
for electric motorcycles, golf carts and go-carts, as well as industrial motor control. It is mainly
supposed to solve noise problems of BLDC motor driving application. KLS controller can not
support sensorless brushess motor for now. Compared to the traditional trapezoidal waveform
control technology, this technique based on sinusoidal wave driving technology can reduce the
operation noise and 1/3 switching loss, which well meets the noise reduction and efficiency
requirements in the application of DC brushless motor. It uses high power MOSFET‟s and,
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, conduct tests, and obtain diagnostic information quickly and easily.
People can program the KLS controller on PC software and Android App. There is one more
choice for customers to program KLS controller now. The APP software is based on Tablet with
Android OS. Customers may add a Z-TEK USB to RS232 cable for programming KLS controller
if they want to use Android Tablet.
Both PC software and Android APP can provide one screen to monitor the controller
parameters. Sometimes people can use a smallAndroid Tablet as display device.
KLS-8080N/NPS is designed by opto-isolated technology. We specify 8-20V 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 is
supposed to work with BLDC motor with hall sensors. KLS-8080NPS can work with
brushless motor with Sin/Cosin speed sensors.
KLS-8080N/NPS controllers include the fuse on the plastic case.
Anyway please try to do identification angle operation before running the motor.

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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.
This is the most important thing.
Chapter 2 Features and Specifications
2.1 General functions
(1) Extended fault detection and protection. Customers can read the error code in PC
software or Android Tablet also.
(2) Monitoring battery voltage. It will stop driving if the battery voltage is too high and it
will progressively cut back motor drive power as battery voltage drops until it cuts
out altogether at the preset “Low Battery Voltage” setting.
(3) Built-in current loop and over current protection.
(4) Configurable motor temperature protection range.
(5) Current cutback at low temperature and high temperature to protect battery and
controller. The current begins to ramp down at 90℃case temperature, shutting down at
100℃.
(6) The controller keeps monitoring battery recharging voltage 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 allows for
configuration, programming and software upgrades using the tablet which must be
based on Android OS now. People can do the same things on PC software by using
a standard USB to RS232 cable instead.
(9) Provision of a +5 volt and +12 volt output to supply various kinds of hall sensors.
(10)5 switch inputs which are activated by connection to 12V. Default to throttle switch,
brake switch, reversing switch, forward switch and Boost switch.
(11)3 analog 0-5V inputs that default to throttle input, Brake analog input and motor
temperature input
(12)Copy signal of one of sensors.
(13)Configurable boost switch. Enables the maximum output power achievable if the
switch is turned on. The effect is the same as full throttle position even if you don‟t
turn throttle at all.
(14) 12V brake switch input used different port from motor temperature sensor. You can use
both brake switch and motor temperature sensor functions at the same time on the latest
version. Pin 25 is 12V brake switch input port.Pin1 is motor temperature sensor input port.
(15)Optional joystick throttle. A bi-symmetrical 0-5V signal for both forward and
reversing.

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(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. Can not support Resolver sensor type.
(18) Brake analog regen mode. This regen mode doesn't need brake switch to support
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. The regen can happen at any speeds until zero speed.
(20)Cruise control. Only can be activated in forward direction.
(21)KLS-8080N/NPS can support Broadcast type CAN bus function. It is 250Kbps.By
default,KLS-8080N/NPS controller includes CAN bus function.
(22)Bluetooth function. Required a small Bluetooth converter which needs to be purchased in
addition from our website. This small converter is only useful for KLS controller.
(23)Can support three speed function 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 drop, fast SVPWM and FOC to achieve very high
efficiency.
3) Electronic reversing.
4) Voltage monitoring on 3 motor phases, bus, and power supply.
5) Voltage monitoring on voltage source 12V and 5V.
6) Current sense on all 3 motor phases.
7) Current control loop.
8) Hardware over current protection.
9) Hardware over voltage protection.
10) Configurable limit for motor current and battery current.
11) Low EMC.
12) Battery protection: current cutback, warning and shutdown at configurable high and low
battery voltage.
13) Rugged aluminum housing for maximum heat dissipation and harsh environment.
14) Rugged high current terminals, and rugged aviation connectors for small signal.
15) Thermal protection: current cut back, warning and shutdown on high temperature.
16) Controller can do auto_Identification angle for different Sine/Cosine Speed sensors. Can
adjust the zero-crossing point and signal amplitude to match different Sine/Cosine speed
sensors.
17) Configurable high pedal protection: the controller will not work if high throttle is detected at
power on.

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18) Current multiplication: Take less current from battery, output more current to motor.
19) Easy installation: 3-wire potentiometer will work.
20) Standard PC/Laptop computer to do programming. There is one more choice for customers
to program KLS controller. Standard Tablet with Android OS to do programming. Need a
Z-TEK USB TO RS232 cable for connecting the controller toApp program in Tablet.
21) User program provided. Easy to use. No cost to customers.
22) Support motors with any 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 Battery Current: < 0.5mA.
•5V or 12V Sensor Supply Current: 40mA.
•Controller logic supply voltage, Logic PWR: 8-20V, pin7 and pin6 which must be isolated
from main battery pack B+/B-.
•Supply Current, PWR, 30mATypical.
•Configurable battery voltage range, B+.
•Standard Throttle Input: 0-5 Volts(3-wire resistive pot), 1-4 Volts(hall active throttle).
•Throttle Input: 0-5 Volts. Can use 3-wire pot to produce 0-5V signal.
•Full Power Operating Temperature Range: 0℃to 70℃(MOSFET temperature).
•Operating Temperature Range: -40℃to 100℃(MOSFET temperature).
•Max Battery Current : Configurable.

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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
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
KLS72701-8080N/NPS
700
350
24-72
86
B
KLS96401-8080N/NPS
400
160
24-96
115
A
KLS96401-8080N/NPS
400
200
24-96
115
B
KLS96501-8080N/NPS
500
200
24-96
115
A
KLS96501-8080N/NPS
500
250
24-96
115
B
KLS96601-8080N/NPS
600
300
24-96
115
B
KLS11401-8080N/NPS
400
160
24-110
132
A
KLS11401-8080N/NPS
400
240
24-110
132
B
KLS11501-8080N/NPS
500
200
24-110
132
A
KLS11501-8080N/NPS
500
300
24-110
132
B
KLS14351-8080N/NPS
350
140
24-144
173
A
KLS14351-8080N/NPS
350
210
24-144
173
B
KLS14401-8080N/NPS
400
160
24-144
173
A
KLS14401-8080N/NPS
400
240
24-144
173
B
KLS14451-8080N/NPS
450
180
24-144
173
A
KLS14451-8080N/NPS
450
270
24-144
173
B
Note: There are two types of cooling heatsink.
A: Aluminum Heatsink B: Aluminum Liquid Cooling Heatsink

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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.
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 surface will enhance thermal performance.
Proper heat sinking and airflow are vital to achieve the full power capability of the controller.
The case outline and mounting holes‟ dimensions are shown below.
Figure 1: With Aluminum Heatsink at the bottom
mounting holes‟ dimensions
(dimensions in millimeters) +/B+/B-/U/V/W:M8

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Figure 2: With Aluminum Liquid Cooling Heatsink at the bottom
mounting holes‟ dimensions
(dimensions in millimeters) +/B+/B-/U/V/W:M8

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Figure3: With Sealed Aluminium Housing
mounting holes‟ dimensions
(dimensions in millimeters) +/B+/B-/U/V/W:M8

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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.
When Boost is disabled in the user program, the pin2 can be used as brake variable regen
mode. When Boost is enabled, the brake analog regen mode is inactivated automatically. Both
Boost and Brake variable regen mode can not be used at the same time.
Figure 4: waterproof connector

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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
(25) 12V brake switch. Yellowish
(22) ECO: Low speed switch input Blue
(33)CAN-H:Greenish(Optional function)
(7) PWR: Controller power supply (input). Pink
(34)CAN-L:Brownish(Optional function)
DJ7091Y-2.3-21 Pin Definition
(15) Micro_SW: Throttle switch input. Gray
(3) Throttle: Throttle analog input, 0-5V. Dark Green
(20) RTN: Signal return. Black
(8) Meter: Copy signal of hall sensors. Dark Gray
(4) 5V: 5V supply output, <40mA. Purple
(2) Brake_AN：Brake variable regen or Boost function. Brown
DJ7061Y-2.3-21 Pin Definition
(21) RTN:Signal return. Black
(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 signal input on KLS-8080NPS】
(16) Hall C: Hall phase C. Dark Blue【There is no hall C signal input on KLS-8080NPS】
Notes: 1. All RTN pins are internally connected.
2. Meter function is to copy either of hall sensors.
3. Switch to 12V is active. Open switch is inactive.
Caution:
•Do not apply power until you are certain the controller wiring is correct and has been
double checked. Wiring faults will damage the controller.
•Ensure that the B- wiring is securely and properly connected before applying power.
•The preferred connection of the system contactor or circuit breaker is in series with the B+
line.
•All contactors or circuit breakers in the B+ line must have precharge resistors across their
contacts. Lack of even one of these precharge resistors may severely damage the controller
at switch-on.

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3.2.2 Standard Wiring
Figure 5: KLS-8080N controller standard wiring

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Figure 6: KLS8080NPS controller standard wiring

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3.2.3 Optional wiring of KLS-8080N/NPS controller
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 controller on pin11
Figure 9: Wiring diagram for motor temperature sensor
NOTE: KLS controller can support KTY84-150, KTY84-130,KTY83-122 thermistors.

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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
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 wheels off the ground before beginning these
tests.
•Do not allow anyone to stand directly in front of or behind the vehicle during the checkout.
•Make sure the PWR switch and the brake is off
•Use well-insulated tools.
•Prohibit trying to connect the controller to user program while the motor is still running,let
alone change the settings in the user program.

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•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. Verify wiring or voltage and the fuse if it does not. The motor
should run faster with increasing throttle. If not, refer to the Table 1 code, and correct the
fault as determined by the fault code.
•Take the vehicle off the blocks and drive it in a clear area. It should have smooth
acceleration and good power.
Chapter 4 Programmable 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 recommended for all applications. Make
sure set the proper parameters before making any test to avoid danger.
Customers can do program on PC software or Android App. The Android Tablet is preferred.
First of all, people need to do Identification angle function for KLS controller before running the
motor. The controller needs to be connected to 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.
Please download the instruction how to use Identification angle function from our website.
www.kellycontroller.com/support.php

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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.
Suggestion: Set according to the practical situation. By default, it is set at 18V.
(2)Over Volt: The max voltage of reporting this fault - Range 18~173, depending on model.
Controller will not operate when battery voltage is higher than the value so as to protect battery
and controller.
Suggestion: Set according to the practical situation.
Here is the max voltage for each model.
72V controller: 86V
96V controller: 115V
120V controller: 144V
144V controller: 173V
Controller Rated voltage
Under Voltage Range (V)
Over Voltage Range(V)
72V
18~86
18~86
96V
18~115
18~115
120V
18~144
18~144
144V
18~173
18~173
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 Limit: Battery Limit Current, Limit the max value of Battery Current. Range: 20~100
Functional description: Set max battery current so as to protect battery. A lower value means a
lower battery output current and better protective effect. But excessively low value will affect
acceleration.
Suggestion: Factory default is 100%.
(5)Identification Angle: Please download the instruction to how to use Identification angle
function from the website.
www.kellycontroller.com/support.php
If you can read 85 in Identification Angle item, that is to say, the system is stable and normal.
Please fill in 170 for Identification Angle item in user program. Then please click Write button in
user program. Please wait a few seconds before restart the power supply. You will see some
info on Monitor screen after power supply is reset. If you see Reset error on the Monitor screen,

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that is to say, the auto_Identification is finished. You can see 85 in the Identification Angle item
again. And the controller will blink error code. This is normal. Please reset the power supply
again. Then everything will be fine. The motor is ready to be drived by the KLS controller.
Range: 85 or 170, nothing else.
(6)TPS Low Err: Hall active pedal, if lower than the value, report the fault of TPS Type. Range:
0~20
(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.
The controller will think the hall throttle is shorted or damaged if the output is beyond the range
from 0.5V to 4.5V.
You can adjust the threshold voltage below or above 0.5V.The controller will report the 3.3 code
to protect the system according to different types of hall 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 0-5V or 3-wire pot for the throttle type. That is
to say, these two settings are only useful for hall active throttle or pedal when you chose throttle
type at 2.
As the same goes, it is valid to adjust the high threshold voltage above 4.5V or below 4.5V.
Usually the hall output voltage is 4.2V Max. If you adjust it to lower value which is near 4.2V,it
may trigger the error code in normal way.
(8)TPS Type: TPS Type, 1:0-5V 3-wire 0-5K pot,5K is normal,2K-20K can be used;2:Hall active
throttle or pedal. Range: 1~2
(9)TPS Dead Low: TPS 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.
(10)TPS Dead High: TPS 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.
(11)Brake sensor type: Brake sensor type for brake variable regen mode:
1:0-5V 3-wire 0-5K pot,5K is normal,2K-20K can be used;2:Hall active throttle or pedal. Range:
1~2