Kelly KHB error 4.1

[bobzilla]

hello guys, I would like to describe a problem to my Kelly KHB bought about a year ago, all of a sudden two days ago when I loaded normally to 135.5 V ( max allowed by the controller : 136V ) at the time of the power on , the red LED has started flashing 4-1.
The error is described as over-current , while the voltage remains less than the maximum allowed.
I had to download the battery pack until the battery voltage V 133.5 to return the green led on! . 33s I have a configuration with li-po and charge a little more than 4V cell is not good , because in this way not i can balance on max since the VCLAMP not be under tension.
I state that the controller has never had excessive heat and never had moisture inside , quele is the internal component that decides the surge ? may have not calibrated for any reason?
Now the warranty has expired , I am available for an eventual opening of the controller and check which part is damaged .... if this is possible.
I am sure that the experience of many I will be able to help solve this problem
Thanks in advance!

 

[Bluefang]

You are very lucky to not have problems up until now. The 136V listed is the ABSOLUTE max, ie it has to have some room to cope with voltage spikes when you get on and off the throttle which even with the input capacitors spike the voltage up to 140+ at times. 135.5V hot of the charger is asking for trouble. Do you have a precharge curcuit?

Have you asked Fany about it? Or emailed Kelly in general? I asked about running the controller to the limit and i got a reply that said it would be touch and go as the controller has a 2% error allowance for the max voltage but could easily cause the controller to cut out and run rought on low speed high torque accelleration. You may have been lucky and got a selection of perfect components in the controller that are now just wearing out through age. I would suggest rewiring the pack for 30S if possible as that should really be the max voltage for that controller.

 

[bobzilla]

Thanks for the reply, actually I wanted to write to Kelly for an answer but I wanted to ask first forum for a faster response and less biased, I knew margin of 2% and the first charge when I saw the Analyst 136V I was happy with what I read.
13 months does not seem a lot for a controller then treated in the best way, but anything can happen ...
The best solution is to get down to 30 or maybe 32s (charged to 4.1 V per cell = 131V), but I'm sorry to disassemble the battery pack just put a brand new 2 weeks ago with a lot of sacrifice and time.
Yes,i have a precharge curcuit :wink:
One question: what may have been incorrectly calibrated within the controller? it depends on the SW I think that there is nothing to be done but if the cause is a component other than I think we can solve.

 

[Bluefang]

If you have a 120V controller and you have been running it just under 136V then all i can say is you are very lucky it has lasted this long.

No idea what could have been changed, I would only be guessing that some component is not running at 110% and that has caused your controller to finally glitch out. From looking at pics of what the inside of the controller looks like i highly doubt you would be able to even get to the component, glue everywhere, let alone fix it with out been extremely skilled at circuit repairs. I have not seen any posts about people been able to modify Kelly controllers on any forums.

 

[garchofa]

This can be your Chance Bob!!!, send me the controller, i can open it and may be i can modify it
You know that i have my electric saw always ready for this!!! :lol:

May be the controller don't work again, but i can get a lot of Fun and a lot of pictures to post here!!!!

Now seriously, should be better if you email to Kelly.

 

[bobzilla]

oohhh what an honor! the great engineer impossible , just three hours ago I sent an e-mail to Fany of Kelly and see what she says.
I talked to some friends in Rome that mount the KBL provided for a maximum of 120V and they told me that the error code normally takes 4-1 after the 117V and the range of 2% is regular.
I wonder why 250 charge cycles to 135.5 sometimes 136V (volt meter margin of error) and after it all together does not accept voltages higher than 133.7 V.

If you want to permanently kill my controller go ahead! but then I will not enjoy the ride with the Cromotor Mammoth V4 .... you'll really bad ...

here "to be afraid," can I write ??

 

[garchofa]

May be now you get the error because you change your Battery pack, and now the drop is smaller!!

Is this possible?

and don't worry about enjoying your Cromotor, when i kill your kelly you can use my Real Ebike/Toilet For Men, Da paura!!!!, ("to be afraid")

 

[bobzilla]

Now with the new batteries the voltage drop has fallen a lot but the problem is not this, then the error occurs immediately at power without any additional load.


da paurosky ... this is in Russian

 

[bobzilla]

hello guys is that I do not write much but I can tell you that I solved the problem of the controller. beginning the error stood at 4.1 133.5V and then down over the weeks up to 112V. Contacted Fany of Kelly sent me a new firmware with the hope of changing the situation, unfortunately, has remained the same as before. The decision of the factory was to propose a control person because according to them the problem was in sw. Too much time, risks and costs made ​​me give the decision to send.
So I completely disassembled the controller and removed with acetone thinner the wax on the circuit (erroneously mistaken for hard resin but it is not).
I immediately saw a small red wire that went from B + connector and power through the whole controller ran to first base circuit stampèato always with the b + signaling.
Thinking that my unit of Mitsubishi Triton D common rail has been linked to a form to understand different values ​​to the control unit with the intention of increasing the pressure diesel ::::::::::::::::: :::: I thought !!! why not do the same with Kelly khb ........ I put in the path of the small red wire (which goes to feed the logic) a Zener diode 75V from the cost of a few ct, almost to the read controller 75V
In just a few minutes to assemble the diode and full charge to 136V, but not before re-programmed controller with a 61V max load values​​. (136 less than 75V). Turning ........... GREEN LED !!! everything ok ..... road test: GREAT !! the Greyborg runs much more ... brutal at the start and infinite extension ............. house happened? there is no more internal protection? does not occur even more annoying internal reset that occasionally came under strain when pushing uphill ........... no abnormal temperature of the houses, always in the media.
Now I understand that it is not a repair to officially hand over to a client, I've done and I personally use the controller ... but the reality is that this work is all about.
I hope that my experience can help some people in my own terms (if these issues have always existed) ... I thank you all and the next !! ciaooo

 

[Bluefang]

That sounds like a awesome result I am assuming by soft resets you mean the times when you pull full throttle and the controller only wants to you to go slow so it kind of shudders and stop start runs the motor.

Do you have any photos of this mod and also would it be possible to do with out removing all the wax? I have a pair of KEB controllers on my bike that have the weakest startup due to the protection circuit. The controllers dont even get more then a degree or 2 past ambient.