Kelly KLS-S: Troubleshooting

General Discussion about large electric scooters and motorcycles and other things with no pedals.
larsb   1 MW

1 MW
Posts: 1932
Joined: Dec 10 2014 5:12am
Location: Gothenburg, Sweden

Re: Kelly KLS-S: Troubleshooting

Post by larsb » Jun 06 2020 7:30am

It’s not exactly a fault though if you set controller higher than the BMS allows. Off course you can then get a cutout.

I’ve gotten cutouts on all KLS controllers i’ve had even without BMS. I think the current regulation isn’t good enough so it throws faults at max output.

Pryside   1 µW

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Joined: Aug 27 2020 7:01am

Re: Kelly KLS-S: Troubleshooting

Post by Pryside » Aug 27 2020 7:22am

I figured it out!! :mrgreen: :mrgreen:
I had so many troubles with the kelly controller. I own the Kelly KLS6018S a 60V 240A Controller. Combined with the MXUS 3K Motor.
My issues: Not much current was possible, cut off/Internal Reset Error with like 40% battery current "Vehicle->Battery Limit" and 90% phase current "Vehicle->Current Percent".
Also light oscillations at many different speeds when accelerating.

Fix: First I noticed that when setting the "Vehicle -> PWM Frequency" which is the frequency the foc current gets applied to the motor, to the lowest setting, from 20KHz to 6Khz, I suddenly was able to achive way higher current settings (95% phase current and 50% Battery Current) I think even 60% battery current was theroetically possible, but thats not what my battery is capable of.

But that lead to a ton of oscillations, even at low speed now I had strong vibrations ratteling the whole ebike.
Fix: I knew something with the way the foc current loop pids work was wrong. So with some trial an error i figured it out:
Setting the Kp,iq "Control->IQ Kp" from 1500 to 400 solved 90% of the oscilations.
And lowering the Ki,iq from 30 to 25 made it even smooter.

Now everything works!
The eBike has the performance I always wanted and doesnt vibrate around insanely.

Other issues like having a hard time connecting over usb were solved by installing UC232 Driver.
If you want instant torque, set the Torque Speed Kp to 9000 and Ki to 400

Here are my Settings now:
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larsb   1 MW

1 MW
Posts: 1932
Joined: Dec 10 2014 5:12am
Location: Gothenburg, Sweden

Re: Kelly KLS-S: Troubleshooting

Post by larsb » Aug 27 2020 10:42am

Still you’re only at 60%.. i’ve run 100%/100% so your settings are still very low. Good it’s at a level that works for you but still no real fix for total performance.

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