How to connect Cycle Analyst to Kelly Controller?

smeagol222 · Nov 10, 2016

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-analyst-connector-controller/

product page: http://kellycontroller.com/keb72601x24v-72v280a6kw-bike-brushless-controller-regen-p-279.html

user manual: http://kellycontroller.com/mot/downloads/KellyKEBUserManual.pdf

teklektik · Nov 10, 2016

No need to open the controller. Use an external shunt wired something like this:

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.

smeagol222 · Nov 23, 2016

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.

smeagol222 · Dec 1, 2016

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

Does this makeshift circuit diagram look right?

teklektik · Dec 1, 2016

smeagol222 said:
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...

smeagol222 · Dec 1, 2016

teklektik said:
smeagol222 said:

Does this makeshift circuit diagram look right?]

Click to expand...

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/datasheets/SmartPrechargerV1-3.pdf

Ecyclist · Dec 5, 2016

smeagol222 said:
teklektik said:

smeagol222 said:

Does this makeshift circuit diagram look right?]

Click to expand...

no.
Wire the (+) connection as shown in the diagram above to pin 1 (PWR) so the keyswitch turns off the display...

Click to expand...

ah nice spot, will do that

Going to use the smart precharger also
http://www.zeva.com.au/Products/datasheets/SmartPrechargerV1-3.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.

smeagol222 · Dec 6, 2016

Ecyclist said:
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: https://endless-sphere.com/forums/viewtopic.php?f=10&t=85164

Ecyclist · Dec 6, 2016

smeagol222 said:
Ecyclist said:

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.

Click to expand...

Hey I'm just starting out with this build, currently waiting on the battery to ship

All the details here: https://endless-sphere.com/forums/viewtopic.php?f=10&t=85164

Thank you and please keep us posted.

Allex · Mar 3, 2021

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"

amberwolf · Mar 3, 2021

https://endless-sphere.com/forums/viewtopic.php?f=4&t=37964&p=1622308#p1622308

Allex said:
Now to another issue. When connecting ca using this schematics:
https://endless-sphere.com/forums/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.

Santacruz · Mar 3, 2021

Ecyclist said:
smeagol222 said:

teklektik said:

smeagol222 said:

Does this makeshift circuit diagram look right?]

Click to expand...

no.
Wire the (+) connection as shown in the diagram above to pin 1 (PWR) so the keyswitch turns off the display...

Click to expand...

ah nice spot, will do that

Going to use the smart precharger also
http://www.zeva.com.au/Products/datasheets/SmartPrechargerV1-3.pdf

Click to expand...

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.

How to connect Cycle Analyst to Kelly Controller?

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