Bricked Kelly KLS controller

Electric Motors and Controllers
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HorstFugger   1 µW

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Bricked Kelly KLS controller

Post by HorstFugger » Apr 17 2017 9:12am

Hi my name is Andi and this is my first post :D

I have a problem with my Kelly KLS7250D (http://kellycontroller.com/kls7250d24v- ... -1337.html). I think I briked it by changing the motor spin direction via the PC interface while the motor was running. Now no RS232 communication is possible and the controller does not move the motor. After having a conversation with Fany from Kelly the can't help me because my controller ran out of warranty and I told them that I opened the controller. When I opened the controller I saw two JTAG interface headers.

I think by reprogramming the firmware the controller can be unbricked.
  • So what programming hardware do I need to flash a new firmware via the JTAG interface?
  • Can someone provide me the firmware or read it from their controller?
  • Is there an other possibility to unbrick the controller?
Thanks

catacon   10 µW

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Re: Bricked Kelly KLS controller

Post by catacon » Apr 18 2017 1:29pm

Kelly's are not field-programmable, so I doubt anyone will have a firmware file you can download.

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macribs   1 GW

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Re: Bricked Kelly KLS controller

Post by macribs » Apr 18 2017 1:51pm

I don't know the Kelly. But as a "thinkerer" I have "hacked", improved usability or swapped firmware on various devices, made mad errors and what not. And I got to say the only time I bricked something has been with not paying attention during firmware upgrades. Are you sure the controller is bricked? One would think you should get an error code if bricked? Maybe electro mechanical rather then software?

As you already has it open, is there any blown fets, fuses or other things that might be the source of your problem?

HorstFugger   1 µW

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Re: Bricked Kelly KLS controller

Post by HorstFugger » Apr 19 2017 4:36pm

Hi macribs, I'm pretty sure that I haven't blown anything so a hardware defect is unlikely. The controller worked as aspected right before I i wrote the spin direction change via the PC softwate to the controller. Now when I start the controller I receive 0x00 in RealTerm and the BREAK Status indicator in RealTerm stays on. The Kelly software on the PC isn't able to talk to the controller and the controller itself shows no reaction to a throttle input. I really don't know if I blew the main µC. It may be possible but this would be really bad hardware design and I don't know how to check if it is dead. So I guess it is a software bug but I'm not sure.

The heart of my controller is a SPC5602PEVLL6 chip http://pdf1.alldatasheet.net/datasheet- ... MLH4R.html
Has anyone programmed the main µC of a Kelly controller via JTAG?
Has anyone ever had a similar problem and solved it?

Thanks
Attachments
OpenedKelly.jpg
opened Kelly controller
OpenedKelly2.jpg
KLS7250D

kristofl   1 µW

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Re: Bricked Kelly KLS controller

Post by kristofl » Jan 24 2018 7:09am

Hello,


I have the same problem with the same controller. I have changed somerhing in the settings while the Bldc was turning. I contacted Kelly and got a firmware file. Buth i cant write it because there is no RS-232 connection possible. I checked it with a scope and there is no answer from the u-processor.

Is it possible to reprogram it with jtag or something else?

Endy   1 µW

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Re: Bricked Kelly KLS controller

Post by Endy » Apr 10 2018 11:44am

Hi Kristofl,
I have the same problem with my kelly Keb controller so can you please send me the firmware file ?
Thanks

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flippy   10 kW

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Re: Bricked Kelly KLS controller

Post by flippy » Apr 24 2018 2:12pm

those firmware files are specific to that model and type.
i tried flahsing a KLS that bricked during driving and could not recover it even with a bootloader and firmware from fany.
they did replace it as it was only used for 3 weeks.
Lithium beats liquid dinosaurs.

Bricoleur1702   1 µW

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Re: Bricked Kelly KLS controller

Post by Bricoleur1702 » Jul 09 2018 4:09pm

Hi

I'm Fabien in France.

I have the same problem with the KLS 7230S and Fany tells me it's dead. I had a firmware because the one he was there was not working for my use, but I have no communication with the controller!
Someone got to troubleshoot this problem?

I had to send information while the engine was running.

You do not think that the warning message in the notice should appear in the software ??

Thank

AlexFerrer   10 µW

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Re: Bricked Kelly KLS controller

Post by AlexFerrer » Aug 30 2018 9:47am

Hi, Last week I received a brand new KHB1440 controller but in never worked.
As the manual instructs I put 24 volts DC on power and ground on return , but I only got a red steady light. (never seen the green led at all)

When I tried to connect to it via USB-RS232 and Kelly's KHB software, it said it could not recognize the controller.

I talked multiple times with their support, they send me a flash burst software, when run, it shows the software connected to the serial port, but could never load the slave burst.

Now they are telling me I have to send it back !

I have many questions..

Kelly's support say they tested the controller twice before shipping. Is it possible that the controller got damaged during shipping? This controller is designed to go on a vehicle, I can't believe that normal FED-EX shipping can damage it so easy. (The box arrive in good condition)

Could the controller have been damaged by static electricity during shipping? The controller just came wrapped on regular shipping foam, no special anti-static materials, and no warnings about that.

As I read on this board, it looks like the controller is on a fault state that does not activate the RS232 interface, so no new firmware can be loaded. Is there anything I can do to test the controller before I send it back?

I can not believe that a $900 piece of equipment does not have a hard reset sequence to return the CPU to a sane state !!!

Any help is appreciated.

Alex in South America.

billvon   1 MW

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Re: Bricked Kelly KLS controller

Post by billvon » Aug 30 2018 5:28pm

AlexFerrer wrote:
Aug 30 2018 9:47am
I can not believe that a $900 piece of equipment does not have a hard reset sequence to return the CPU to a sane state !!!
You are assuming a simple reset will fix things. If the firmware is corrupted, or there is a hardware failure, a "hard reset" won't help you.
--bill von

AlexFerrer   10 µW

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Re: Bricked Kelly KLS controller

Post by AlexFerrer » Sep 02 2018 6:14pm

I guess you are right.. it might be something bigger than a corrupt bios.. in any case, Kelly is sending me a new one.

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