Added LED to throttle, now it wont stop

[kwheels]

I recently purchased a new 48v with battery meter thumb throttle, and added an LED for the status of my controller to the throttle.
In an attempt to do this cleanly, I spliced the 48v wire into the power switch(inside the throttle), and used the power switch wire as the 48v wire, freeing up the original 48v wire to use as the LED+ wire, for the LED I added. For the LED- i tapped out of the ground that the hall effect sensor was attached to.(note: this ground also splices out to the 48v board. If it would be beneficial to tap out of that one instead, I can do that, but I feel like it shouldn't make a difference

Original Wire Colors...........New Colors/Function
Red------>+5v..................Red
Black---->Ground..............Black
White--->Speed Signal.......White
Green--->+48v................Led+
Brown--->On/Off Switch.....48v/On/Off Switch
Yellow--->On/Off Switch.....Yellow

The battery meter works fine, as does the power button(which i was a bit worried about at 48v), but after the first initial acceleration, the throttle seems to be stuck at about 10-15%. Its not so fast its dangerous, and its honestly a nice economical cruise speed, but to come to a stop I have to turn off the controller.
Controller is a Kelley KDS48200
I have a feeling I can probably fix this through programming, but I havn't been able to get the USB adapter to work yet, and dont have a computer with RS-232

How can i stop my unintended acceleration?

 

[Jeremy Harris]

I think that what's happening is that the current that the LED is sinking into the ground wire at the throttle end of the cable is raising the zero-throttle voltage enough to stop the controller going to zero rpm. To test this, just temporarily disconnect the LED -ve from the ground and see if the problem goes away. If it does, then you need to try and run another ground wire up to the unit for the LED.

If this is the cause, then it can't be programmed out, as there's no way of adjusting the throttle range from the programming interface.

Jeremy

 

[kwheels]

im pretty sure there is a way to adjust the throttle range through programming...

Throttle effective starting position-----20%
Throttle effective ending position------80%

are two of the programmable parameters, and the stock ratings on the controller.
I'll try it without the LED tho, and see if thats causing it

Edit: I just tried it with the LED removed, and its still doing the same thing. I'll have to figure out if its just this new throttle causing this, or if I've caused something else to happen. Unfortunatly, its a new throttle that I modded before I tested, so I dont know if the throttle may have not been reading 0-5v from the start

 

[Jeremy Harris]

im pretty sure there is a way to adjust the throttle range through programming...

Throttle effective starting position-----20%
Throttle effective ending position------80%

are two of the programmable parameters, and the stock ratings on the controller.
I'll try it without the LED tho, and see if thats causing it

Edit: I just tried it with the LED removed, and its still doing the same thing. I'll have to figure out if its just this new throttle causing this, or if I've caused something else to happen. Unfortunatly, its a new throttle that I modded before I tested, so I dont know if the throttle may have not been reading 0-5v from the start

OK, it may well be that the zero position if off, as you originally suspected and the throttle programming needs changing. My fault about the programming - I didn't spot that this was a Kelly..............

Jeremy

 

[kwheels]

Heres a really crappy picture inside the throttle. I dont know if this will help anyone, but maybe it will make something more clear.
I called Kelly and tried to figure out how to connect it, and was informed I need the controller to rs232 adapter, which they promptly sent out. Hopefully this issue is just caused from a non 0-5 throttle, not something I've changed

 

[kwheels]

finally got the rs232 to controller adapter from kelly, and it programmed right up first try. bumped the throttle up to 30%, and cruise controls gone! my new throttle just wasnt 0-5 stock.

To clarify, programming fixed this problem