Hall error and identify error on Kelly controller

[Deepak]

Hello Team,

I bought a new Kelly controller KLS7212N to control my 48V 750W Unite motor. On the first instance everything worked well. All of a sudden it gives hall error and identify error on the kmc user app and 3,4 beeps. The manual suggests it is a wiring fault or motor hall sensor bad or controller bad.

But I can run the Motor with another unbranded controller.
Also the error persist if I change to a different motor.

So it is the controller which is at fault, can anyone suggest how to repair the Kelly controller or how to rectify this fault?

Thanks,
Deepak

 

[amberwolf]

It's probably noisy hall signals. Kellys don't do well with those.

Try separating the hall wires from the phase wires starting at the point they exit from the motor, all the way to the hall plug on the Kelly, and keep the hall wires away from the metal frame of whatever the motor is mounted to, at least until testing is done.

If that doesn't work, there is a way to change from 5v to 12v for your hall sensors, which may improve the signal level enough to make them work. It's in the manual here: https://kellycontroller.com/wp-content/uploads/kls-nm/KellyKLS-N-UserManualV2.7.pdf Just make sure the sensors in your motor are capable of working at 12v first (most are).

 

[Deepak]

Thank you so much for your suggestions, I will perform these and update this thread

 

[Deepak]

Hello, I separated the phase and hall wires and provided 12v to the hall sensor, the hall error and identify error gone, but then it gave pedal error 3,3. Manual say this happens if the voltage to hall sensor is above 4.5v. Do I need to adjust any parameter.

I set the TPS type to 1 from 2 and the pedal error is also gone. But if I accelerate nothing happens, the power to throttle become 0v. So I took another 12v red wire from controller and provided to throttle no change if I throttle motor does not spin. Please help

Thanks,
Deepak

 

[amberwolf]

Hello, I separated the phase and hall wires and provided 12v to the hall sensor, the hall error and identify error gone, but then it gave pedal error 3,3. Manual say this happens if the voltage to hall sensor is above 4.5v. Do I need to adjust any parameter.

Did you try just separating the phase and hall wires, *without* using 12v (just using 5v)? If so, what was the result? If not, you should try that.

Combining troubleshooting steps is not recommended--try only one thing at a time, and note the exact results during each step (and include the things you changed each time), so that you know what worked and what did not, and what changed and what did not, so you know what things are actually helping you and what things are not.

I set the TPS type to 1 from 2 and the pedal error is also gone. But if I accelerate nothing happens, the power to throttle become 0v. So I took another 12v red wire from controller and provided to throttle no change if I throttle motor does not spin.

If you use a hall-based throttle, 12v may damage it if it is not one of the ones capable of that. If the kelly's throttle input is not capable of handling the 12v, it may also damage the controller itself. I only glanced at the manual but it seems to say the throttle input is only 0-5v, so you'd have to check with Kelly to see if it is now damaged.

If you are using a pot throttle, then 12v wont' damage the throttle, but if the kelly only takes up to 5v on the input, then moving the throttle past the point at which it outputs 5v into that input could damage the controller. You'd have to ask Kelly about that.

The TPS type has to match the type of throttle you are using. The manual says which one is which, so you should follow that.

You said "the power to throttle become 0v". What exactly does that mean? Do you mean the 5v that powers the throttle drops to 0V? Or do you mean the output of the throttle itself drops to 0v? When exactly does either of these happen? Meaning, what exactly, step by step, are you doing before you see this happen?

 

[Deepak]

Sure I will do step by step and update the results. When the 12v given to hall sensors at that point of time if you measure the hand throttle input is 0V.

When 5V input is given to hall sensor and hand throttle from controller they both measure 1.32V is that sufficient?

 

[Deepak]

The error is same after trying the suggested. Thanks for your help I decided to move on to a different controller.