Anyone use the Kelly KDZ controller ?

[EBJ]

I originally built a small EV with a Kelly KD controller and everything worked great.

I now have a KDZ controller installed on another EV (because kelly is discontinuing the KD model for the KDZ model)
and I am having a few issues with it.

I was wondering if anyone here is currently using a Kelly KDZ controller?

Thank You.

 

[EBJ]

bummer.
Looks like I may have been the guinea pig for this controller.
Hopefully I can get the issues resolved. Communicating with kelly Controllers is a bit of a challenge.
Hopefully they will pull through and figure out what is going on.

 

[EBJ]

Ok, since apparently no one is using the Kelly KDZ controller,
I would like to re-word my question:

Is anyone using any Kelly Controller having the same issues where regen-brakes turn OFF (and vehicle starts coasting) at a low speed ?


Thank You.

 

[Gow864]

Ok, since apparently no one is using the Kelly KDZ controller,
I would like to re-word my question:

Is anyone using any Kelly Controller having the same issues where regen-brakes turn OFF (and vehicle starts coasting) at a low speed ?


Thank You.

I had this happen a couple of times with a KBL48301, I turned down the regen current and it stopped. No idea why it happened, i guess something was happening the controller didn't like.

Gow.

 

[EBJ]

Ok, since apparently no one is using the Kelly KDZ controller,
I would like to re-word my question:

Is anyone using any Kelly Controller having the same issues where regen-brakes turn OFF (and vehicle starts coasting) at a low speed ?


Thank You.

I had this happen a couple of times with a KBL48301, I turned down the regen current and it stopped. No idea why it happened, i guess something was happening the controller didn't like.

Gow.

Thank you, I'll be sure to try that and report back shortly.
I would like to point out it is happening to me in both "analog" and "brake-switch" modes. So I'm not very hopeful this will solve my particular situation.
willing to give it a shot though.

Thanks again.

 

[EBJ]

OK, I tried it with no luck.

Set at 80%, the regen brakes still "click" off at low speeds.
Set at 33% the regen brakes still "click" off at low speeds.

What I have noticed is that the regen clicks off more noticeably if you are asking for 100% regen power than if you are asking for only 10% regen power.
I'm almost certain this is a motor-controller firmware issue, as there is no way I am tripping any over-voltage cut-offs with regen at such slow speeds.

Thank you for the suggestion,
but for now the problem still remains.

Kelly said they will attempt another firmware swap in the next few days.
The first firmware swap got rid of a couple other issues, so I have high hopes this next one will get rid of this regen-brake problem.

 

[Doctorbass]

same thing on my KBL 220A 120V

But i think it might depend on the Back EMF of the motor that is too low at low rpm causig the controller to try working harder to rise the voltage to be able to push current into the battery, and it finally turn turn off the regen at a given low rpm.

I regen at up to 5kW on my 30s lipo with the 5305 at like 75kmh but at low speed like 10-0kmh controller begin having difficulty to boost the back emf voltage from the motor to the battery cause it spin too low to produce enough voltage to be boosted to the appropriate current level to regen.

Doc

 

[EBJ]

same thing on my KBL 220A 120V

But i think it might depend on the Back EMF of the motor that is too low at low rpm causig the controller to try working harder to rise the voltage to be able to push current into the battery, and it finally turn turn off the regen at a given low rpm.

I regen at up to 5kW on my 30s lipo with the 5305 at like 75kmh but at low speed like 10-0kmh controller begin having difficulty to boost the back emf voltage from the motor to the battery cause it spin too low to produce enough voltage to be boosted to the appropriate current level to regen.

Doc

When I used a KD w/ a 24V battery, the thing would allow for constant regen.
It would never shut off at low speeds. It would never be able to completely stop the vehicle, but it would get it down to about 3 mph and keep it there.

This KDZ I am using on the same vehicle, with the same type of motor, but with a 36V battery. The regen seems to work great until about 4-5 mph when it feels like it is reaching it's last regen-point and then just shuts off regen, and then I am coasting again. If you do this going down a steep hill, the regen will slow you to about 4 mph, then it will cut off, and not turn back on until you cycle the brake again. So you can get coasting to a higher speed before you have time to cycle the brake to get it to 4 mph again. Something that the KD never did.

So are you guys saying some of the Kelly Controllers you are using don't have "constant-regen" and also turn off regen at slow speeds (then coasting) ?
I never expected regen to stop the vehicle completely, but I sure didnt expect it to just turn off at low speeds.

The KD controller explicitly says "supports constant regen" - and I have found that to be true.
The KDZ controller doesn't explicitly say that, but I was told that all the features of the KD controller tranfer over to its replacement (the KDZ controller)

 

[fany]

All the regen issues were removed from KDZ.Customized a firmware for special application.

 

[Doctorbass]

All the regen issues were removed from KDZ. Customized a firmware for special application.

Fany,

Thanks for having sent us the replacement for our 2000$ deffective controller.

I just hope that it will not have that regen problem again too... I would love to have the Kelly to run as smooth as the infineon controller!.. Smooth at low speed during high acceleration and smooth on the regen to as low as 5km/h!

Doc

 

[EBJ]

All the regen issues were removed from KDZ.Customized a firmware for special application.

How do the regen brakes function in the new firmware?

Will the brakes still cut-out at low speed?
Will the brakes take you to a complete stop?
Will the brakes always be engaged so long as the brake switch is held?

 

[fany]

The back EMF is too low at low speed.It is hard to be detected by the controller with Mosfet sampling.
So it may stop at low speed.
The new KDZ-GDZ or GDV controller used the new technics which will provent the regen quit at low speed.
In other words,the new technics will detect the back EMF in accurate way by using a device inside the controller.

KLS-8080I used this device also.

The special function regen is triggered as long as the brake switch is turned on.This function needs to be customized.

 

[Hillhater]

..wow ! A 3+ year delay on that reply ?
..better late than never I guess