MACK said:
With regards to grounding, traditionally motorcycles would use the frame as a ground/return to the neg side on the battery, do people do the same with a DC converter on electric bikes? or would all return run through wires back to the converter?
There's a recent thread about that here:
https://endless-sphere.com/forums/viewtopic.php?f=30&t=106825&p=1565199&hilit=ground+frame#p1565199
whcih while it's about the controller, it applies well enough to all grounding.
One piont not covered in it is bearings. If you have stuff on your bars or fork and you use frame as ground, you're runing current thru your bearings.
My other question is, is the high voltage system ground contained within the battery/controller/motor circuit keeping it isolated from frame and rest of it, as long as all of those wires are insulated?
Depends on your system. YOu'd ahve to check if it's all isolated, but typically it should be unless there is a fault (which is why there can be problems using frame as ground...when something faults and also connects itslef to the frame).
From what I think I'm understanding about regenerative brake with this Kelly controller (KLS7245N) is I can have the output from my 2 wire 12V brake signal split and send one to the brake lights and the other to the controller pin 25.
You can use a simple relay to isolate everything if you like, probably a DPST will work fine. There are threads about brake lights and switches that cover this; at least one or two I've posted in recently.
But if you have the option for proportional or analog regen, I highly recommedn taht, otherwise all you get is on/off braking, whcih means you don't want to set it too high or teh sudden jerk is discomfiting at best, and under the wrong conditions has the potential for cuasing you problems.
Then you can use a brake or clutch lever to control a COT (cable oeprated throttle) (there's trheads about that too) that then controls the braking amount. Most MC brake levers already have brake light switches in them, so no need to even connect that to any of the controller stuff at all.