How to go through the setup procedure, including the angle identification function, for a Kelly motor controller. The model I'm using is KLS7245N. The controller is matched to a QS 4kw hub motor (QS205 4000W V2) and is for my EV motorcycle conversion project, Dream-e. Good info for if you're wiring up a DIY custom electric motorcycle, go kart, scooter, skateboard, bicycle, or even an electric car!
Steps to program the controller:
1. Wire up everything but have the contactor switched off
2. connect the battery ground to B-
3. switch on the contactor
4. ensure that the motor turns when the throttle is lightly applied, in either direction
5. open the program and connect to the controller (will take a few tries?)
6. set all the motor parameters (# of poles, etc)
7. set the identification angle to 170
8. save:
a. write
b. read again and check that its still there
c. quit the program
d. disconnect the battery
e. wait 3+ seconds
f. connect the battery again
9. the motor should begin moving, this is the identification angle function working
10. wait about three minutes and wait until you hear a beeping noise from the control. This is the "reset error" telling you that it needs to be reset again. You can connect to the bluetooth adapter with the app to verify this error code.
a. disconnect the battery from the controller and wait 3+ seconds
b. reconnect battery
c. open config program
d. read the parameters
e. check that the identification angle has been changed to 85
f. check that the motor turns when given throttle
g. check full speed!
h. set all the vehicle parameters in the config software, save, reset, etc.
I found that when I got to step 4, the throttle would not cause the motor to spin. This worried me, but I discovered that it was because the "three way switch" option was enabled. And neither pins for reverse or forward were getting 12v, so it assumed neutral and therefor did not spin the motor.
How to use the bluetooth adapter and Kelly's AC Aduser android app:
1. scan for bluetooth devices before powering up the controller
2. power up the controller
3. scan for bluetooth devices again and look for a new one, it might be labelled 20102202 or something
4. the PIN is 1234
5. open the AC Aduser app
6. select Bluetooth com
7. connect by pressing the leftmost black button, then tap the numbers
8. press the 3rd button from the left, to read
9. change the parameters where needed
10. press the rightmost button for write
11. press the 2nd to left button, to disconnect
Here are some of my parameters that I configured:
- set the nominal motor current to 90 (this is used by the angle identification function).
- set the battery current limit to 60%. My battery can do 60 amps continuous, the controller can do 100 amps continuous. The rest of the math is pretty simple.
- max speed can be set to 1140 - because that’s max rpm of my motor. FYI 1140rpm for a ~23 inch diameter wheel will give me a theoretical top speed of 78 mph. I'll want to balance the rear wheel before I do anything near that!
- excell time should be 10 (thousands of a second)
- keep these as set up from factory: torque speed kp, torque speed kj, speed error limit
wiring the controller:
endless-sphere...
wiring the contactor:
endless-sphere...
parameters and optimizing:
endless-sphere...
Tips and tricks:
- configure it so that it won’t continuously discharge the battery more than it can handle without cooling, aka continuous max discharge
- wire all the batteries together in parallel before building the battery pack, and let them balance out for a few hours. Higher voltages will transfer to lower voltage cells.
- charger needs to be selected for the battery chemistry - because a Li-ion battery will charge to a higher voltage than a LiFePO4 battery, for example
- the 12v system GRD needs to be isolated from the high voltage system GRD
- to get Domino throttle to work with Kelly controller: add three 1k Ohm resistors in parallel to the ground wire. endless-sphere...
- if motor is getting too hot: ebikes.ca/prod...
- if building a diy battery pack: "build in series first, so there would be N low current series connections, evenly distributed current. Then I run parallels, creating redundancy and equalization functions ... lighter gauge wires required.”
- Kelly controller’s wiring diagram was very confusing. The fat red wire from the battery connects to (NC) not the port with a red circle.
28 авг 2024
