Need help configuring Kelly + Cyclone

A

andrenoites

100 W
Joined
Aug 29, 2013
Messages
149
Location
Portugal
Hello

When pushing the engine more than half throttle the engine cutoff.
If I throttle instantly again the engine responds but only until half throttle then cutoff again.

Seems to me not temperature related (the motor and controller are barely warm)
I'm guessing it is a power limiter but don't know why or were to configure.

My bike specs are as follow:

mid drive 1680w cyclone motor at 48v
Kelly controller KBS48101
4 x 6s 5000mha Lipos with C20 continuous discharge rate (c30 max)
2 meters of 10AWG cable from backpack to controller (reducing cable length helps?)

this is the configuration of my controller:

kelly1.JPG
kelly2.JPG
kelly3.JPG
kelly4.JPG
kelly5.JPG

Any suggestion would be appreciated,
Tks
 
I'm unfamiliar with this controller, but it looks like you will need to hook up a couple of LEDs yourself.

According to the manual:

  • Male Connector Pin Definition
    • (14) REV_SW: Reverse switch input. Deep Blue
      (6) RTN: Signal return or power supply return. Black
      (11) Green-LED: Running indication. Dark Gray
      (12) Red-LED: Fault code. White
      (9) Relay: Main contactor driver, <200mA. Blue
      (7) PWR: Controller power supply (input). Pink
      (10) Alarm: To drive reverse beeper, <200mA. Yellow

kelly KBS-48101.png
 
Tks for the help. I will try that after i buy some leds.

Do you know if the controller aluminium case needs to be grounded?
 
andrenoites said:
Do you know if the controller aluminium case needs to be grounded?
Click to expand...
No, it doesn't.
Your bicycle frame should not be connected to anything - it should be isolated. The LEDs will get their Gnd from pin 6.
You can just make the LED leads really short so the LEDs are near the controller - they're really not too useful except for fault diagnosis. No need to run wires all over the bike... :D
 
teklektik:

The error is 3,2 - Internal reset

"May be caused by some transient fault condition like
a temporary over-current, momentarily high or low
battery voltage. This can happen during normal operation."

My guess is low battery voltage because it always happen at >50% load

Could it be the 2 meters long cable (10awg) from the battery to the controller that is reducing the amperage?

My batteries are 4 x 6s 5000mha Lipos with 20C constant discharge 30c peak

Tks


ps: configuring the motor max speed to 60% stops the cutoff, any idea why this is happen?
 
This really needs someone with some Kelly and Cyclone expertise (not me), but...

You have a 100Amp controller and a 1700W motor at 50v. To stay in spec (not that we ever over-amp our controllers here :D ) you should have a battery current of 1700W/50v ~= 35A. The manual seems to indicate that the 'battery current' and 'motor current' are equivalent to the Xie Chang (Infineon) controller 'rated current' and 'phase current' respectively. The two adjustments in setup let you change these settings 20%-100% or 20A-100A.

From the somewhat ambiguous error code you got, I think that your motor is drawing too many amps and the controller needs to be limited a bit - this may be causing the fault. I would think that (for 'safe' settings) you want to reduce the battery current to 35% to limit to 35A or 1700W. A rule of thumb for geared hub motors is to use a roughly 2:1 phase amp to rated amp ratio so you might try setting the 'motor current' to twice the 'battery current' or 70A = 70%.

Again, I know nothing about either the motor or controller and am just winging it, but I think this may cure the fault codes. Quite probably you can increase these settings and push the motor harder, but I don't know...

  • You might try going to your first post, pressing 'edit' then change the subject to 'Need help configuring Kelly + Cyclone', then press 'submit'. This will change the thread title and hopefully attract some folks with more specific knowledge to help you out.
 
I had a problem with my Q100 motor where the motor would run to 95% no load speed and then cut out. Same story with different controllers. One the Halls is not working, but only above a certain motor rpm, some sort of "sympathetic" vibration of the sensor, or centrifugal force or something acting on the Hall, at higher motor speed. Could be a similar problem. My Halls test fine with an "ebike tester" device I have. Both of the controllers I mentioned do work fine with a different Q100 motor, so not a controller problem. As I never get to the no-load speed where I also actually need assistance, it is not a problem to use the motor with this strange Hall issue.
 
Tks for the help teklektik, later I will try to change the settings as you sugested.

chvidgov.bc.ca said:
I had a problem with my Q100 motor where the motor would run to 95% no load speed and then cut out. Same story with different controllers. One the Halls is not working, but only above a certain motor rpm, some sort of "sympathetic" vibration of the sensor, or centrifugal force or something acting on the Hall, at higher motor speed. Could be a similar problem. My Halls test fine with an "ebike tester" device I have. Both of the controllers I mentioned do work fine with a different Q100 motor, so not a controller problem. As I never get to the no-load speed where I also actually need assistance, it is not a problem to use the motor with this strange Hall issue.
Click to expand...

I don't think its the same problem because if I push full throttle at low motor speed the cutoff kicks in.
I guest its not speed related, I'm thinking more in a power related problem.
 
teklektik said:
This really needs someone with some Kelly and Cyclone expertise (not me), but...

You have a 100Amp controller and a 1700W motor at 50v. To stay in spec (not that we ever over-amp our controllers here :D ) you should have a battery current of 1700W/50v ~= 35A. The manual seems to indicate that the 'battery current' and 'motor current' are equivalent to the Xie Chang (Infineon) controller 'rated current' and 'phase current' respectively. The two adjustments in setup let you change these settings 20%-100% or 20A-100A.

From the somewhat ambiguous error code you got, I think that your motor is drawing too many amps and the controller needs to be limited a bit - this may be causing the fault. I would think that (for 'safe' settings) you want to reduce the battery current to 35% to limit to 35A or 1700W. A rule of thumb for geared hub motors is to use a roughly 2:1 phase amp to rated amp ratio so you might try setting the 'motor current' to twice the 'battery current' or 70A = 70%.

Again, I know nothing about either the motor or controller and am just winging it, but I think this may cure the fault codes. Quite probably you can increase these settings and push the motor harder, but I don't know...

  • You might try going to your first post, pressing 'edit' then change the subject to 'Need help configuring Kelly + Cyclone', then press 'submit'. This will change the thread title and hopefully attract some folks with more specific knowledge to help you out.
Click to expand...

With your help and the specs from this kit I think I will thy this new setting

http://www.ego-kits.com/motor/

I know the ego kit is exactly the same motor and same controller so I will configure like this:

2400w peak at 50v = 48A battery current and 96A motor current

Does this make any sense? :)
 
I'm starting to get frustrated

No mater the settings I chose the controller still cutoff at 21amp when I accelerate quickly
Recently I changed max motor current to 60% and Max battery to 50% and still cutoff with internal reset error (3,2)

I don't see anyone else with this kind of problem, could it be that I have received a faulty controller? did this happen frequently?

Sorry for all the mess, I just wish to get my bike running good
 
I like to thank all for the help

Changing the throttle setting from 3 wire pod to Hall fixed the problem :)

I 'm very happy with the result, now the bike is super easy to ride and powerfull

Tks,
André

20131024_223655.jpg
 
I cannot see the battery. What kind of battery do you use?
 
https://www.kellycontrollers.eu/kbs48101x
Hello, I have this KELLY controller.
The problem is that this model is no longer manufactured and the manufacturer does not have the drivers to download on its website.
Can you give me the drivers to configure KELLY controller on my computer?
Thank you
 
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