Search found 45 matches

by bigchief
Oct 25 2019 1:50am
Forum: E-Bike Technical
Topic: Kelly Controller has no torque, jerks motor
Replies: 27
Views: 697

Re: Kelly Controller has no torque, jerks motor

Thanks for the advice, I got a hot air gun on Amazon and it was great for desoldering the pegs. The only problem was when clearing out the PCB holes with my plunger-type solder sucker, the plunger "jerked" when I hit the button and the shock knocked an SMD resistor off the board that was a few milli...
by bigchief
Oct 21 2019 2:49am
Forum: E-Bike Technical
Topic: Kelly Controller has no torque, jerks motor
Replies: 27
Views: 697

Re: Kelly Controller has no torque, jerks motor

Bumping since I was scrolled off the first page and could still use some help. Is there any reason I can't butt-solder my new mosfets directly to the leads I clipped? Those old leads are in there really good and I don't want to risk burning up the PCB trying to get them out, so can I get away with s...
by bigchief
Oct 09 2019 10:15pm
Forum: E-Bike Technical
Topic: Kelly Controller has no torque, jerks motor
Replies: 27
Views: 697

Re: Kelly Controller has no torque, jerks motor

A hot air station is highly recommended, as a thick powerful soldering iron will fry the PCB quite easily. Best plan is to cut the broken FETs off and desolder the pins, then use a solder pump to suck off the solder from the PCB holes. I cut off the broken FETs, even in this state the pins are very...
by bigchief
Oct 07 2019 1:08pm
Forum: E-Bike Technical
Topic: Kelly Controller has no torque, jerks motor
Replies: 27
Views: 697

Re: Kelly Controller has no torque, jerks motor

I checked the FET you posted. IMHO one of the best replacements is the well trusted IRFB3077. An excellent FET with almost the same specs (Vmax=75V), but WAY lower RDSon of 3mO compared to 8mO. That means is dissipates about A TENTH of the heat the RJK type does. So your controller will stay cooler...
by bigchief
Oct 04 2019 1:37am
Forum: E-Bike Technical
Topic: Kelly Controller has no torque, jerks motor
Replies: 27
Views: 697

Re: Kelly Controller has no torque, jerks motor

I got home and tested all the Kelly MOSFETS by touching their leads with multimeter continuity tester, using this guide: https://www.youtube.com/watch?v=RkWy1EirEu8 All four of the circled fets are shorted, across any/all of their 3 leads. The rest seem to be OK. Stupid question, but is this method ...
by bigchief
Oct 03 2019 2:29pm
Forum: E-Bike Technical
Topic: Kelly Controller has no torque, jerks motor
Replies: 27
Views: 697

Re: Kelly Controller has no torque, jerks motor

Your experience clearly proofes that it was the wrong phase/hall combination as amberwolf told you. Now that you killed the controller you will not make the motor run again properly w/o repairing the controller first. Most probably two phase wires touched, or you touched one of the battery wires wi...
by bigchief
Oct 03 2019 4:42am
Forum: E-Bike Technical
Topic: Kelly Controller has no torque, jerks motor
Replies: 27
Views: 697

Re: Kelly Controller has no torque, jerks motor

it's much simpler than that. Simply swap the phases around (since you have the halls soldered), just swap any two of them and see if it gets better. If it doesn't, swap the other two. If that doesn't, swap the last color pair. One of those should improve things. If it runs backwards, either use the...
by bigchief
Oct 03 2019 4:19am
Forum: E-Bike Technical
Topic: Kelly Controller has no torque, jerks motor
Replies: 27
Views: 697

Re: Kelly Controller has no torque, jerks motor

I checked again and verified that I have continuity through all the wiring from the controller/wheel/battery, and that all phase/hall wiring is correct. I also did as some Youtube video recommended and used the multimeter to measure 20k ohms from B+ on the controller to the different phase wires (ap...
by bigchief
Oct 03 2019 2:45am
Forum: E-Bike Technical
Topic: Kelly Controller has no torque, jerks motor
Replies: 27
Views: 697

Re: Kelly Controller has no torque, jerks motor

Yeah, it's gotta be something with the phase/hall. When I sat down for a while now and thought about it, I recalled that with the original controller (much weaker than the Kelly controller, on paper) I was hitting the throttle while not on the bike, and the torque nearly ripped the bike out of of my...
by bigchief
Oct 03 2019 1:03am
Forum: E-Bike Technical
Topic: Kelly Controller has no torque, jerks motor
Replies: 27
Views: 697

Re: Kelly Controller has no torque, jerks motor

I went and soldered the motor Hall sensors instead of relying on the JST connection. Then I temporarily increased the fuse rating on my battery so it doesn't blow so quickly, and tried riding around. The motor still feels "gritty" with little torque at low speed; it makes "click" noises many times a...
by bigchief
Oct 03 2019 1:02am
Forum: E-Bike Technical
Topic: Kelly Controller has no torque, jerks motor
Replies: 27
Views: 697

double post
by bigchief
Oct 02 2019 7:24pm
Forum: E-Bike Technical
Topic: Kelly Controller has no torque, jerks motor
Replies: 27
Views: 697

Re: Kelly Controller has no torque, jerks motor

Gotcha, I dug up a second throttle in my parts bin to compare against (same as this eBay listing https://www.ebay.com/itm/202731390785). I guess they are both Hall Sensors, because if I plug a multimeter to the black and middle pins while the throttles are hooked up to the Kelly controller and power...
by bigchief
Sep 30 2019 3:41pm
Forum: E-Bike Technical
Topic: Kelly Controller has no torque, jerks motor
Replies: 27
Views: 697

Re: Kelly Controller has no torque, jerks motor

The red LED does not throw an error code. I'll try soldering the phase wires instead of relying on the JST connectors when I get home.
by bigchief
Sep 30 2019 2:53am
Forum: E-Bike Technical
Topic: Kelly Controller has no torque, jerks motor
Replies: 27
Views: 697

Kelly Controller has no torque, jerks motor

I couldn't figure out how to set the 48v LVC on the controller included with my cheap ebike kit to 36v, so I decided to get a used Kelly KBS48101L-L Controller instead, which I snagged from an eBay listing: https://www.ebay.com/itm/183888487486 I successfully connected this Kelly controller to my PC...
by bigchief
Jul 31 2019 5:12pm
Forum: E-Bike Technical
Topic: Upload Your Circuit Schematics & Requests Here...
Replies: 530
Views: 182248

Re: Upload Your Circuit Schematics & Requests Here...

This thing is really kicking my butt since I'm reduced to trial and error. I took out the SMD for the 2000 and 2200 ohm resistors and replaced them both with higher and lower resistance. I also took out the 25k resistor and replaced that with higher and lower resistance. None of these value changes ...
by bigchief
Jul 27 2019 1:58pm
Forum: E-Bike Technical
Topic: Upload Your Circuit Schematics & Requests Here...
Replies: 530
Views: 182248

Re: Upload Your Circuit Schematics & Requests Here...

Removing the resistor makes it cut off just about instantly. I think I'm messing with the wrong resistor. Maybe it's actually the really tiny one next to it marked "222" and not the "2001". I was using file hosting services because the forum caps at 512kb which isn't that high of a resolution. Here'...
by bigchief
Jul 26 2019 5:13pm
Forum: E-Bike Technical
Topic: Upload Your Circuit Schematics & Requests Here...
Replies: 530
Views: 182248

Re: Upload Your Circuit Schematics & Requests Here...

I have a 48v ebike controller that I'm trying to adjust the LVC down for a 36v battery. I'm really sleep deprived at the moment and my brain isn't working well enough to sort out the exact resistor I'm to replace: Check out this thread: https://endless-sphere.com/forums/viewtopic.php?f=2&t=101242&p...
by bigchief
Jul 26 2019 5:04pm
Forum: E-Bike Technical
Topic: I think I need a new controller.......LVC occuring 39V, not 30V.
Replies: 16
Views: 704

Re: I think I need a new controller.......LVC occuring 39V, not 30V.

I have a very similar looking controller: https://imgur.com/a/Z2u2Zfv Mine controller is 48v, and I want it to run on my 36v battery. If I have the 36v battery charged to 42 volts it will run until I try to hit a high speed or climb a hill, when it cuts out from the voltage drop. I tried to do the s...
by bigchief
Jul 26 2019 3:22am
Forum: E-Bike Technical
Topic: Upload Your Circuit Schematics & Requests Here...
Replies: 530
Views: 182248

Re: Upload Your Circuit Schematics & Requests Here...

I have a 48v ebike controller that I'm trying to adjust the LVC down for a 36v battery. I'm really sleep deprived at the moment and my brain isn't working well enough to sort out the exact resistor I'm to replace: https://imgur.com/a/Z2u2Zfv Would anyone be able to eyeball that pcb and point out the...
by bigchief
Feb 23 2018 12:23am
Forum: E-Bike General Discussion
Topic: Most efficient end-to-end pedal generator?
Replies: 6
Views: 635

Re: Most efficient end-to-end pedal generator?

I can't really help with the hook up, but for sure your bike hub motor will make a decent, efficient, generator. Others have produced the same thing commercially using a basic direct drive rear hub motor. Use the power to keep a cheap lead 12v battery full. I wouldn't want to use a lead-acid as the...
by bigchief
Feb 22 2018 2:44am
Forum: E-Bike General Discussion
Topic: Most efficient end-to-end pedal generator?
Replies: 6
Views: 635

Most efficient end-to-end pedal generator?

I'm trying to power a PC from a bike pedal generator, and have some parts at my disposal, but I wanted to figure out the most efficient setup possible. The PC uses a "Pico power supply", so it is powered from 12 volts DC. It consumes between 40-160 watts depending on if I am gaming with the GPU or n...
by bigchief
Feb 16 2017 5:39pm
Forum: Battery Technology
Topic: How should I design this EV battery system?
Replies: 7
Views: 641

Re: How should I design this EV battery system?

Not into solar, but why not just hook the panels up in series to get the desired voltage of ~350VDC, then hook them direct through power diodes to the battery pack. Well, charging needs to be more controlled and tapered when charging lithium ion. As long as you never exceed max no load voltage, the...
by bigchief
Feb 13 2017 5:19pm
Forum: Battery Technology
Topic: How should I design this EV battery system?
Replies: 7
Views: 641

Re: How should I design this EV battery system?

Not into solar, but why not just hook the panels up in series to get the desired voltage of ~350VDC, then hook them direct through power diodes to the battery pack. Well, charging needs to be more controlled and tapered when charging lithium ion. Your project is a bit out of scope for most people o...
by bigchief
Feb 06 2017 6:00pm
Forum: Battery Technology
Topic: How should I design this EV battery system?
Replies: 7
Views: 641

How should I design this EV battery system?

I currently have 14 Tesla 24v battery modules (75kwh total) and I'm going to wire them in series for 312v nominal for an EV. There's two ways I want to charge the battery pack: 1) From any standard J1772 public charge station (PlugShare, etc.) at a minimum of 6.6kw charge rate 2) This is a box-van t...
by bigchief
Sep 13 2016 11:55am
Forum: E-Bike Non-hub Motor Drives
Topic: Would this pinion with rim-rack drive idea work?
Replies: 8
Views: 956

Re: Would this pinion with rim-rack drive idea work?

It's an idea that seems simple at first but will probably be a lot of work to make it effective. Aside from manufacturing the ring, tooth meshing will be a problem as the teeth won't be parallel due to the difference in inside and outside circumference. You'd need a pinion with slightly tapered tee...