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How to connect Cycle Analyst to Kelly Controller?

Posted: Nov 10 2016 8:22am
by smeagol222
I heard a special plug might be needed? I really dont want to open up the controller and solder things around
like this http://www.ebikeschool.com/add-cycle-an ... ontroller/


product page: http://kellycontroller.com/keb72601x24v ... p-279.html

user manual: http://kellycontroller.com/mot/download ... Manual.pdf

Re: How to connect Cycle Analyst to Kelly Controller?

Posted: Nov 10 2016 9:49am
by teklektik
No need to open the controller. Use an external shunt wired something like this:
CA3-KEB.png
Wiring for CA3 - CA2 is similar but needs a little different throttle hookup.
CA3-KEB.png (183.52 KiB) Viewed 3011 times
If you are running 50-60A battery continuous current or less, you can use the more compact molded external shunt instead and just wire it as described in the Guide - just wire either fat red Vbatt+ wire from the molded shunt to pin 1 (PWR) above instead of to the battery as illustrated in the Guide - the other fat red wire can be left disconnected.

This is the wiring for a CA3 where the throttle and ebrake go to the CA. The CA2 hookup is identical except for the throttle/ebrake - see the CA3 Unofficial Guide 'Appendix D. Adding a CA-DP Connector to a Generic Controller' for details.

Re: How to connect Cycle Analyst to Kelly Controller?

Posted: Nov 23 2016 3:42pm
by smeagol222
Good to know- thanks for this info. I also confirmed with kelly controller also

they said below and gave me this PDF
All the wires are outside of the controller.
They are located on the J2 cables.
All the wires are soldered on the J2 cable and got a 6pin SM connector finally for CA connector.

Re: How to connect Cycle Analyst to Kelly Controller?

Posted: Dec 01 2016 11:16am
by smeagol222
I thought that for my use CA was a bit of an overkill. $20CAD dc voltmeter/ammeter should do the trick
100A_DC_Digital_Power_Meter_Energy_Monitor_Module_Voltmeter_Ammeter_with_Shunt___eBay.jpg
100A_DC_Digital_Power_Meter_Energy_Monitor_Module_Voltmeter_Ammeter_with_Shunt___eBay.jpg (58.08 KiB) Viewed 2926 times
Does this makeshift circuit diagram look right?
kelly-wiring-ammeter.jpg
kelly-wiring-ammeter.jpg (78.11 KiB) Viewed 2333 times

Re: How to connect Cycle Analyst to Kelly Controller?

Posted: Dec 01 2016 12:52pm
by teklektik
smeagol222 wrote:Does this makeshift circuit diagram look right?]
no.
Wire the (+) connection as shown in the diagram above to pin 1 (PWR) so the keyswitch turns off the display...

Re: How to connect Cycle Analyst to Kelly Controller?

Posted: Dec 01 2016 9:33pm
by smeagol222
teklektik wrote:
smeagol222 wrote:Does this makeshift circuit diagram look right?]
no.
Wire the (+) connection as shown in the diagram above to pin 1 (PWR) so the keyswitch turns off the display...
ah nice spot, will do that

Going to use the smart precharger also
http://www.zeva.com.au/Products/datashe ... erV1-3.pdf

Re: How to connect Cycle Analyst to Kelly Controller?

Posted: Dec 05 2016 12:36pm
by Ecyclist
smeagol222 wrote:
teklektik wrote:
smeagol222 wrote:Does this makeshift circuit diagram look right?]
no.
Wire the (+) connection as shown in the diagram above to pin 1 (PWR) so the keyswitch turns off the display...
ah nice spot, will do that

Going to use the smart precharger also
http://www.zeva.com.au/Products/datashe ... erV1-3.pdf
I like your streamlined set-up. I'm in the process of my second build and I would like to make it as compact as possible. Not using CA3 is one of my goals. Can you post what size of the motor and Kelly controller you are using? Do you get smooth acceleration?
How is the smart precharger working for you?
Sorry about so many questions. I'm still on the steep learning curve.

Re: How to connect Cycle Analyst to Kelly Controller?

Posted: Dec 06 2016 6:00am
by smeagol222
Ecyclist wrote: I like your streamlined set-up. I'm in the process of my second build and I would like to make it as compact as possible. Not using CA3 is one of my goals. Can you post what size of the motor and Kelly controller you are using? Do you get smooth acceleration?
How is the smart precharger working for you?
Sorry about so many questions. I'm still on the steep learning curve.
Hey I'm just starting out with this build, currently waiting on the battery to ship

All the details here: viewtopic.php?f=10&t=85164

Re: How to connect Cycle Analyst to Kelly Controller?

Posted: Dec 06 2016 11:32am
by Ecyclist
smeagol222 wrote:
Ecyclist wrote: I like your streamlined set-up. I'm in the process of my second build and I would like to make it as compact as possible. Not using CA3 is one of my goals. Can you post what size of the motor and Kelly controller you are using? Do you get smooth acceleration?
How is the smart precharger working for you?
Sorry about so many questions. I'm still on the steep learning curve.
Hey I'm just starting out with this build, currently waiting on the battery to ship

All the details here: viewtopic.php?f=10&t=85164
Thank you and please keep us posted.

Re: How to connect Cycle Analyst to Kelly Controller?

Posted: Mar 03 2021 11:28am
by Allex
Guys, when I connect "hall A" to "Yel spd 5" on CA3 the hall stops working, upon disconnection of this wire it works again. How to solve this issue? Tried other halls with same issue. Interesting that on another bike with same controller and motor it works but CA on that bike is really old, one of the first ones.
Solved this with connecting diode between hall A" and "Yel spd 5"

Re: How to connect Cycle Analyst to Kelly Controller?

Posted: Mar 04 2021 12:45am
by amberwolf
viewtopic.php?f=4&t=37964&p=1622308#p1622308
Allex wrote:
Mar 03 2021 3:36pm

Now to another issue. When connecting ca using this schematics:
viewtopic.php?f=2&t=84739
Which one? there are several on that thread

When I connect "hall A" to "Yel spd 5" on CA3 for it to able to read speed, the hall stops working, upon disconnection of this wire it works again.
When connecting a diode in line, halls works fine but still no speed reading.
Upon connecting another CA the speed works fine and halls works even without a diode as it should be! What could it be?
is the other ca setup with exaclty the same settings and exactly teh same wiring?

If not, then whatever si wrong is whatever the difference in setings and or wiring.

Re: How to connect Cycle Analyst to Kelly Controller?

Posted: Mar 04 2021 2:47am
by Santacruz
Ecyclist wrote:
Dec 05 2016 12:36pm
smeagol222 wrote:
teklektik wrote:
smeagol222 wrote:Does this makeshift circuit diagram look right?]
no.
Wire the (+) connection as shown in the diagram above to pin 1 (PWR) so the keyswitch turns off the display...
ah nice spot, will do that

Going to use the smart precharger also
http://www.zeva.com.au/Products/datashe ... erV1-3.pdf
I like your streamlined set-up. I'm in the process of my second build and I would like to make it as compact as possible. Not using CA3 is one of my goals. Can you post what size of the motor and Kelly controller you are using? Do you get smooth acceleration?
How is the smart precharger working for you?
Sorry about so many questions. I'm still on the steep learning curve.
Just to jump in with a comment.
I have been using one of these pre chargers for a year now and it is fine.
Does exactly what it should and I have never had a problem.
5p20s battery pack into Sabvoton 96120.
Pre charger is run 12v via dc/dc and powers a 200amp 12v solenoid.