Kelly KSL Controllers User Manual
Contents
1. There are no user serviceable parts inside the controllers Do not attempt to open the controller as this will void your warranty However periodic exterior cleaning of the controller should be carried out The controller is a high powered device When working with any battery powered motor proper safety precautions should be taken that include but are not limited to proper training wearing eye protection avoidance of loose clothing hair and jewelry Always use insulated tools 4 1 Cleaning Although the controller requires virtually no maintenance after properly installation the following minor maintenance is recommended in certain applications e Remove power by disconnecting the battery starting with battery positive e Discharge the capacitors in the controller by connecting a load Such as a contactor coil resistor or a horn across the controllers B and B terminals e Remove any dirt or corrosion from the bus bar area The controller should be wiped down with a moist rag Make sure that the controller is dry before reconnecting the battery e Make sure the connections to the bus bars if fitted are tight To avoid physically stressing the bus bars use two well insulated wrenches 4 2 Configuration You can configure the controller with a host computer through either an RS232 or USB port e Disconnect motor wiring from controller e Do not connect B throttle and so on The controller may display fault code in some c2. suitable for fans water pumps air conditioner compressors fridge compressor applications and etc It uses high power MOSFET s and PWM 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 Kelly KSL Sensorless Motor Controller User s Manual V 1 2 Chapter 2 Features and Specifications 2 1General functions 1 Extended fault detection and protection The LED flashing pattern indicates the fault sources 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 Built in current loop and over current protection Configurable motor temperature protection range Current cutback at low temperature and high temperature to protect battery and controller The current begins to ramp down at 90 Ccase temperature shutting down at 100C 6 Configurable and programmable with a host computer though RS232 or USB Provide free GUI which can run on Windows XP 2000 Windows 7 and Vista recommend using Kelly Standard USB To RS232 Converter 7 Provision of a 5 volt output to supply various kinds of sensors including Hall effect type 8 Reversing switch Closing t
3. Kelly KSL Sensorless Motor Controller User s Manual V 1 2 Kelly KSL Brushless Motor Controller User s Manual Devices Supported KSL24100 KSL24150 KSL24200 KSL24300 KSL36100 KSL36150 KSL36200 KSL36300 KSL48100 KSL48150 KSL48200 KSL48300 KSL48400B KSL48500B KSL72100 KSL72150 KSL72200 KSL72300 KSL72400B KSL72500B KSL96150 KSL96250 Kelly KSL Sensorless Motor Controller User s Manual V 1 2 Contents REI e Vekene e re EE 2 e Kee 2 Chapter 2 Features and Specifications 3 2 RE Rn le ee EE 3 EE 3 2 9 ERT el lele uuu aaa squa bg Ale erea eden ech acenaat ut 4 2 4 Name Regulation E 4 Chapter 3 Wiring and Installation AAA 5 3 1 Mounting the Controller EE 5 Eed 6 3 3 Installation Check EE 10 Chapter 4 Maintenance a 15 e E Elle Te WEE 15 4 2 Configuration EE 15 Table 1 LED e E 16 Green LED Code eet eege 16 Red LED EE 16 Contact EE 18 Kelly KSL Sensorless Motor Controller User s Manual V 1 2 Chapter 1 Introduction 1 1 Overview This manual introduces the Kelly KSL 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 LLC KSL sensorless and brushless series motor drivers and controllers are developed by Kellycontrols LLC independently It is
4. Sensorless Motor Controller User s Manual V 1 2 10 CAN bus high temporary unavailable 11 CAN bus low temporary unavailable 12 Reserved 13 RTN Signal return or power supply return 14 Red LED Fault code The pin is PWR for S N less 08XXXXXX J2 Pin Definition 1 PWR Controller power supply input RTN Signal return or power supply return RTN Signal return Motor temperature input temporary unavailable Throttle analog input 0 5V Brake analog input 0 5V temporary unavailable 5V 5V supply output lt 40mA Micro_SW Throttle switch input temporary unavailable 9 Reversing switch input 10 Brake switch input temporary unavailable 11 Hall phase C temporary unavailable 12 Hall phase B temporary unavailable 13 Hall phase A temporary unavailable 14 RTN Signal return ee mm gt EC Notes 1 All RTN pins are internally connected RTN is internally connected to B 2 Two PWR pins J1 1 and J2 1 are internally connected Switch to return 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 t
5. address in last page 12 Kelly KSL Sensorless Motor Controller User s Manual V 1 2 Step 5 Kelly ESL Series Controllers Configuration Program 1 1 K wee Kelly Controllers http www KellyControlier com Sensorless Setting z Duration of starting ramp 7 v Sensorless Fault auto restart 8 Enable Disable Reset Waiting Time 9 105 v Description 6 The key to setting these demands is to accelerate the motor to the end speed without slipping or excessive mechanical vibration The best way to set these demands is to observe the rotor while starting and listen to the sound that the motor makes when it is energized 4s the starting routine executes most motors will make a ticking noise with frequency proportional to the ramp speeds If you hear the ramp speed increasing but the rotor appears to be spinning slowly or just oscillating in a stationary position then the ramp demands probably need to be increased lt If the rotor appears to be accelerating properly but there seems to be excessive motor l l L Vibration over current trips or excessive noise during ramping the ramp demands are probably set too high Configuration Wizard In most cases you will want to set the Ramp End Demand parameter 5 to 15 higher than the Ramp Start Demand parameter 7 In general you should start with a relatively long ramping time to ensure the motor is starting properly 4 ramping time between 2 and 4 seconds should be appropria
6. equal or lower than 72V 18V to 120V for 96V controllers e Supply Current PWR 150mA Configurable battery voltage range B Max operating range 18V to 1 25 Nominal Voltage 8V to 30V for rated equal 24V Standard Throttle Input 0 5 Volts 3 wire resistive pot 1 4 Volts hall active throttle e Analog Throttle Input 0 5 Volts Producing 0 5V signal with 3 wire pot e Reverse Alarm Main Contactor Coil Driver Meter lt 200mA temporary unavailable Full Power Operating Temperature Range 0C to 50C controller case temperature Operating Temperature Range 30C to 90C 100C shutdown controller case temperature Motor Current Limit 1 minute 100A 500A depending on the model Motor Current Limit continuous 50A 250A depending on the model Max Battery Current Configurable 2 4 Naming Regulations The naming regulations of Kelly BLDC motor controllers KSL48100 x x The eighth letter represents regeneration O non regeneration with regereration The sixth and seventh letters the max current 10 The fourth and fifth letters represent nominal voltage The first three letters represent Kelly s sensorless motor controller Kelly KSL Sensorless Motor Controller User s Manual V 1 2 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 if necessary shielded with a cover to protect it from water and c
7. ery volts and configuration 2 Regeneration over voltage Controller will have cut back or stopped regen 3 This only accurate to 2 upon Overvoltage setting DDD Low voltage error 1 The controller will clear after 5 seconds if battery volts returns to normal 2 Check battery volts amp recharge if required aaan Over temperature warning 1 Controller case temperature is above 90 C Current will be limited Reduce controller loading or switch Off until controller cools down 2 Clean or improve heatsink or fan 2 1 DD Motor did not start Motor did not reach 25 electrical RPM within 2 seconds of start up Hall sensor or phase wiring problem 2 2 DD DD Internal volts fault 1 Measure that B amp PWR are correct when measured to B or RTN 2 There may be excessive load on the 5V supply caused by too low a value of Regen or throttle potentiometers or incorrect wiring 3 Controller is damaged Contact Kelly about a warranty repair 2 3 DD DDD Over temperature The controller temperature has exceeded 100 C The controller will be stopped but will restart when temperature falls below 80 C 2 4 DD anann Throttle error at power up Throttle signal is higher than the preset dead zone at Power On Fault clears when throttle is released 16 Kelly KSL Sensorless Motor Controller User s Manual V 1 2 3 1 DDD Freq
8. have a lot of inertia such as a large diameter Fan blade may need a longer holding time to allow the rotor oscillations to decay The lock times For low inertia loads can generally be set to a very low value to allow the motor ta start quickly Cancel Previous Ne Finish 1 Please choose appropriate motor standard voltage according to name plate of your motor or from your motor supplier 2 Please choose appropriate motor standard rom according to name plate of your motor or from your motor supplier 3 Please choose appropriate motor poles according to name plate of your motor or from your motor supplier 4 Demand Used For Lock Position If the Lock Position Demand parameters are set too high the rotor will oscillate when it reaches the lock positions If they are too low the rotor will not move to the reference position Try increasing or decreasing the Lock Position Demand parameters until the rotor moves quickly to the two lock positions with a minimum of oscillation 5 Lock Position Time Loads that have a lot of inertia such as a large diameter fan blade may need a longer holding time to allow the rotor oscillations to decay The lock times for low inertia loads can generally be set to a very low value to allow the motor to start quickly 11 Kelly KSL Sensorless Motor Controller User s Manual V 1 2 6 Demand Used At Start of Ramp and Demand Used At End of Ramp The key to set these demands is to accelerate the mo
9. he motor should run faster with increasing throttle If not refer to the Table 1 LED code and correct the fault as determined by the fault code e Take the motor off the blocks and drive it in a clear area It should have smooth acceleration and good power if sensorless parameters are set correctly 10 Kelly KSL Sensorless Motor Controller User s Manual V 1 2 3 4 Begin To Use Please read this instructions seriously and adjust parameters carefully before using our sensorless controller Detailed description of sensorless page of GUI Step 4 Kelly ESL Series Controllers Cont zeupation Program 1 1 wee Kelly Controllers http www KellyController com Sensorless Setting Motor Standard Voltage 1 Motor Standard rpm 2 1500 J I Motor Poles 3 M Demand Used For Lock Position 4 Lock Position Time 5 gt 5 E Demand Used At Start of Ramp 6 Demand Used At End of Ramp 6 Description 1 2 3 please choose appropriate motor standard voltage motor standard rpm and motor poles according to name plate of your motor or from your motor supplier 4 IF the Lock Position Demand parameters are set too high the rotor will oscillate when it reaches the lock positions IF they are too low the rotor will not move to the reference position Try increasing or decreasing the Lock Position Demand parameters until the rotor moves quickly to Configuration Wizard the two lock positions with a minimum of oscillation 5 Loads that
10. heir contacts Lack of even one of these precharge resistors may severely damage the controller at switch on V 1 2 Battery Precharge Resistor 1KQ 10W MAIN CONTACTOR Kelly KSL Sensorless Motor Controller User s Manual 3 2 2 Wiring of BLDC Motor Controller ponpa aq LA sat pued 1909 GITP ATTI ETR ue ITO nos WIAA lt OLTFSALM 91 3 nug p mat euondo st 79150901 Wmug p Aq p ajemdod s p st snq NFD 7 9 uo q3e iq 10 10 3u1 o3 Jnd JaAay Sutitu to Xu 31020 g ama Amas 256214 Teusts AS 0 ndyno pa t d pue sTuurutr pus oxu 0 NIY PUL AS Ay Teuts ponp se pasn aq wed pugenud de A 31ON rt NIN GTIPA tI et pausmssg NS El lt an TI Paus pauessy TI IT pauassg TNV I TNV ormsawg H NV2 0l ENV reme 6 MS sag SLS 6 xizecxa AC gt CS 8 MS org xg ze sa s kna RSS OTIP s F L mdno AS NIG L 9 N awg am m 9 gt amon MIS fF spsg mrc SS NIS pasy Z NIQ pasy Z 2 1 amd W a Ieuondo lt DG i JaZZNg 32514149 TALA BIAI al of a el al K EI i G AC YS z epad aeg As 0 ATT 15 2 o ya Nn E L a Figure 4 Standard Wiring for KSL Controllers V 1 2 Kelly KSL Sensorless Motor Controller User s Manual IKO 10W LC Precharge Resistor Main Contactor Panpa 20 LM ss mu tq pued yuo OTT t OTT Ia uu UO nos Way Ay lt lt OFT FSALM 01 yneg p uray euo
11. ndo st z0ystuLIaT zx ynegap q paremdodap st snq NFI g uo 16310 10 10131003 md MN SULA po Ame 310190 g Aw ApMdas ased AS 0 ndjno o pasn aq wed puema od ILON a fo Pd eg AS 0 00V 2 Diode JOOP DAT ssatistae SM WC yous N AbT SEO Ze eg EI Pausa NIN EI TI pauasay pauasay TI U pausa TNYD IT OL MSs H ENV OL AS sassa das 6 a L mdmo as L oe Tue dg BW vs fg xicaxa AC Gg CZECH ait Pad zzz Figure 5 BLDC controller preferred wiring 24V supply is preferred Kelly KSL Sensorless Motor Controller User s Manual V 1 2 3 2 3 Communication Port A RS232 port is provided to communicate with host computer for calibration and configuration Crepes te O O 9 O O Figure 6 standard RS232 Interface 3 3 Installation Check List Before operating the motor complete the following checkout procedures Use LED code as a reference as listed in Table 1 e Make sure the wire is connected correctly e Turnthe PWR switch on The LED should blink and the Green LED keeps on when the controller runs under sensorless mode If this does not happen check continuity of the PWR and return e The fault code will be detected automatically at restart e Turn the sensorless switch on or off 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 T
12. o ground is to activate 9 O 5V Default to throttle input 10 11 GARD x we 2 2 Features Intelligence with powerful microprocessor 2 Synchronous rectification ultra low drop and fast PWM to achieve very high efficiency 3 Current limit 4 Battery current limiting available doesn t affect taking off performance 5 Configurable limit for motor current 6 Low EMC 7 LED fault code 8 Battery protection current cutback warning and shutdown at configurable high and low battery voltage 9 Rugged aluminum housing for maximum heat dissipation and harsh environment 10 Rugged high current terminals and rugged aviation connectors for small signal 11 Thermal protection current cut back warning and shutdown at high temperature 12 Current multiplication Take less current from battery output more current to motor 13 Easy installation 3 wire potentiometer will work 14 Motor stall protection 15 Up to 17 000 electric RPM Electric RPM mechanical RPM motor poles 16 Standard PC Laptop computer is used to do programming No special tools needed 17 User program provided Easy to use No cost to customers Kelly KSL Sensorless Motor Controller User s Manual V 1 2 2 3 Specifications e Frequency of Operation 16 6kKHz Standby Battery Current lt 2mA e5V Sensor Supply Current 40mA Controller supply voltage range PWR 8V to 30V for 24V controllers 18V to 90V for controllers rated
13. onditions but it doesn t affect programming or configuration e Use straight through RS232 cable or USB Converter provided by Kelly to connect to a host computer Provide gt 18V either J2 pin1 or J1 pin14 to PWR Wire power supply return to any RTN pin Download the free configuration software from http www kellycontroller com support php Caution Make certain that the motor is disconnected before trying to run the Configuration Software Configuration software will be regularly updated and published on the website Please Update your Configuration Software regularly You must uninstall the older version before updating When setting Hall Sensor Type in GUI do not use Auto Check This has been deleted from the newer configuration software versions 15 Kelly KSL Sensorless Motor Controller User s Manual V 1 2 Table 1 LED CODES Green LED Codes LED Code Explanation Solution Green Off No power or 1 Check if all wires are correct Switched off 2 Check fuse and power supply Green On Normal operation That s great You got solution Green amp Red are both On 1 Software still upgrading 2 Supply voltage too low or battery too high 3 The controller is damaged Contact Kelly about a warranty repair Red LED Codes LED Code Explanation Solution D DD Over voltage error 1 Battery voltage is too high for the controller Check batt
14. ontaminants 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 in Figure 1 Tall 62 millimeters Figure 1 mounting holes dimensions dimensions in millimeters Kelly KSL Sensorless Motor Controller User s Manual V 1 2 3 2 Connections 3 2 1 Front Panel of BLDC Motor Controller Five metal bars and two plugs J1 J2 are provided for connecting to the battery motor and control signals in the front of the controller shown as Figure 2 Figure 2 Front panel of BLDC motor controller B battery positive B battery negative A Output U 1 A phase B Output V 2 B phase C Output W 3 C phase P Oe Figure 3 The connecting diagram of J1 and J2 SC O ll O I rere J1 Pin Definition 14 O 12 O O 13 O 1 PWR Controller power supply output The pin is Red 8 O LED for S N less 08XXXXXX O 2 Current meter lt 200mA temporary unavailable SM Og O S 3 Main contactor driver lt 2A temporary unavailable KE 4 Alarm To drive reverse beeper lt 200mA 5 RTN Signal return 6 Green LED Running indication 7 RTN Signal return 8 RS232 receiver 9 RS232 transmitter Kelly KSL
15. poles 8 13 Kelly KSL Sensorless Motor Controller User s Manual V 1 2 4 Adjust target voltage percent of locking period set 1 here noload depend on motor load 5 Lock time set 2 seconds here depend on motor load 6 Demand Used At Start of Ramp it is usually 1 or 2 higher than Demand Used For Lock Position set 2 here noload depend on motor load Demand Used At End of Ramp it is usually 5 or 15 higher than Demand Used At Start of Ramp set 3 here noload 7 Duration of Starting Ramp set 4 seconds here depend on load Operation Instruction 1 Please check whether throttle input voltage is zero before turning sensorless switch on otherwise your motor will not start 2 The red led lights up after sensorless switch is on 2s It indicates motor begins to enter lock and ramp mode and throttle input is invaild now when red led goes out and green led lights up it indicates motor switchs into sensorless state sucessfully and you can use throttle to adjust motor speed now 3 Please wait until the motor stops running completely then can you turn sensorless switch on to start motor once again 4 Please turn sensorless switch off and check whether throttle input voltage is zero before using reverse switch you can also change direction by directly adjusting any two of the three phase wire sequence connected to controller 14 Kelly KSL Sensorless Motor Controller User s Manual V 1 2 Chapter 4 Maintenance
16. rmal 2 Check if motor is stalled by accident The Red LED flashes once at power on as a confidence check and then normally stays Off 1 2 means the Red flashes once and after a second pause flashes twice The time between two flashes is 0 5 second The pause time between multiple flash code groups is two seconds 17 Kelly KSL Sensorless Motor Controller User s Manual Contact Us Kelly Controls LLC Home Page http Awww KellyController com E mail Support KellyController com Phone 01 224 637 5092 V 1 2 18 Kelly KSL Sensorless Motor Controller User s Manual 19 V 1 2
17. te For most motor and load combinations You will find that loads with greater inertia require a longer ramp time For proper acceleration 4s the ramp time is decreased you may also have to increase the Ramp Start Demand and Ramp End Demand parameters to avoid rotor slipping during startup 8 Enable or disable auto restart Function if sensorless state run error 9 Set reset waiting time after sensorless running error Note This option is effective only after auto restart Function is enabled Cancel Previous N i Finish 7 Duration of Starting Ramp In general you should start with a relatively long ramping time to ensure the motor is starting properly A ramping time between 2 and 4 seconds should be appropriate for most motor and load combinations You will find that loads with greater inertia require a longer ramp time for proper acceleration As the ramp time is decreased you may also have to increase the Ramp Start Demand and Ramp End Demand parameters to avoid rotor slipping during startup 8 Sensorless Fault auto restart Enable or disable auto restart function if switchs to sensorless state error from ramping 9 Resart Waiting Time Set restart waiting time after sensorless running error This option is effective only after auto restart function is enabled Parameters set example Motor standard parameters 48V 1500RPM 8 poles 1 Choose motor standard voltage 48V 2 Choose motor standard speed 1500rpm 3 Choose motor
18. tor to the end speed without slipping or excessive mechanical vibration The best way to set these demands is to observe the rotor while starting and listen to the sound that the motor makes when it is energized As the starting routine executes most motors will make a ticking noise with frequency proportional to the ramp speeds If you hear the ramp speed increasing but the rotor appears to be spinning slowly or just oscillating in a stationary position then the ramp demands probably need to be increased If the rotor appears to be accelerating properly but there seems to be excessive motor vibration over current trips or excessive noise during ramping the ramp demands are probably set too high In most cases you will want to set the Ramp End Demand parameter 5 to 15 higher than the Ramp Start Demand parameter NOTE When setting options 4 5 and 6 please gradually add them from the minimum value until the motor is latched ramping and running to sensorless smoothly and successfully Do not set a higher value at the beginning or it will cause over current even destroy your controller Usually you only need to set three parameters motor rated voltage motor rated speed motor poles according to your motor type We have setted other parameters to appropriate value when leaving factory unless special requirement If you meet other problems when operating our sensorless controller or setting parameters you can email us to the
19. uent reset 1 The controller will stop driving when detects too many resets 2 Mostly because of B or return wiring Use the heavier and cleaner return wires For dual controllers bond B of both controllers together with a heavy cable or copper strip 3 May be caused by over current Set max current to be lower 4 Arestart will clear the fault 5 Please contact Kelly if it happens repeatedly 3 2 DDD DD Internal reset May be caused by some transient fault condition like a temporary over current momentarily high or low battery voltage This can happen during normal operation 3 4 DDD aaan Non zero throttle on direction change Controller won t allow a direction change unless the throttle or speed is at zero Fault clears when throttle is released 4 1 aaan D Regen or Start up over voltage Motor drive is disabled if an over voltage is detected at start up or during regen The voltage threshold detection level is set during configuration 4 2 aaan an Start to sensorless error 1 Insufficient BEMF to acquire increase ramp end speed 2 Starting ramp not adjusted correctly to make zero crossings visible 3 Ramp Start Speed parameter 6 causing oscillatory rotation 4 3 aaan DDD Sensorless lost Check that excessive speed overshoot does not occur 4 4 aaan anann Stalled error 1 Check if the load of motor is heavier than no
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