It's been a while since I last posted and I have a few updates. Back in March after powering up the bike from being idle over the winter period the Kelly controller red led stays on for about 20 minutes before it starts flashing. The codes are 2,2 and 3,1. I have to turn the power off then back on again before it works normally. There had not been any changes to the wiring since I had left it standing, I have assumed that the cold conditions had somehow allowed moisture to affect the internals. Any way once I got the bike going I was then having problems with my 12V system, I had a Kelly 72V/12V DC converter, this was my mistake, I should have bought the 72V/13.5V version. So I replaced it with the 72V/13.5V version and that cleared up the 12V system faults. We are now in April and I'm test riding the bike with the 70Ah pack, I'm riding round the village at 30 and 40 mph to test the range when the controller cuts in and out again. It seems to be a low voltage and I get the 2,2 (Internal voltage fault) and 3,2 (transient fault). I contacted Kelly Controls and they gave me some tips and how to diagnose the fault. I will strip the bike down and have a look at the controller during the May Half term holiday.
This evening the weather has improved and its 22 degrees C, I fire up the bike and the controller goes straight to green! I am making another assumption here that the condition is temperature related. I will monitor it for now and see what happens.
Any way I have some good data for those wishing to convert a 600 ICE bike to electric:-
1. 74V nominal is not enough voltage, top speed is 75 mph with 15T/47T ratio and my 85kg's on the bike
2. Acceleration with the 600A Kelly Controller set at max amps takes about 11 to 14 seconds to get to 60mph
3.Make sure, if you use a DC/DC converter for your 12V system, it can still operate at the lowest level of your battery discharge capacity. (I need 60V to 84V), the 13.5V DC converter lower limit is 68V, this might be why my controller kept cutting out.
4.RC LiPo packs are okay for prototyping and proof of concept but not for everyday use, I am now looking at getting some EIG or Enerdel pouch cells once I find the money.
5.At 74V nominal the voltage sagged to 70V with the throttle full open trying to get to 70 mph.
6. At 70mph motor speed = 2800 rpm
I have an Arduino installed which receives pack voltage, battery discharge current, rear wheel speed and temperature readings for ambient, battery, controller and motor. I will write a script on the arduino to carry out some data logging.
Below is my temporary wireless digital dashboard,
Here are some screen shots
There are more and I can create what ever screen data I want.
That's all for now, thanks to all those who have helped me in this project, I welcome your comments.
Last edited by Bernel
on May 06 2017 2:52am, edited 1 time in total.