Kelly Controls first impression

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reikiman
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Kelly Controls first impression

For the Honda Elite project I had a brilliant idea (or brain fart) to try out the Kelly Controls controller. This is the same Honda Elite project which Alias mentioned.. as she is participating. The bike has a 48v "4000 watt" motor I bought from Craig (deafscooter) a year ago and the low end Kelly controller is 200 amp. So, ah, this controller will do double what Craig claimed is the capacity of the motor. Ought to make for a good test.

The controller just arrived and I thought to write up initial impressions - it hasn't been installed, just looking over the manual etc. I think someone else bought one of these controllers, right?

The box is in the same style as the curtis controllers, but a silvery color (aluminum) rather than their preferred basic black. The box is very sturdy and appears to be watertight. A welcome departure from the Curtis style is the large number of connectors. The other controller makers, Curtis, Alltrax and Logisystems, 4QD, all use a minimalized number of connectors.

Kelly has separate connections for power, reverse, throttle, ground, three different switch inputs, a horn, both resistive and hall effect throttle, serial port, etc.

The M-/B+/B- connectors are large spade posts to which you screw cables, as is typical. But the hole for inserting the screw is pretty narrow.

They include in the box high value resistors and diodes as per the wiring diagram AND they include a serial port cable and gender changer. Very complete on this end. The wiring diagram is very detailed and thorough unlike the sketchy (and incorrect) diagram which shipped with the last alltrax controller I bought.

An interesting detail -- the unit I bought is rated for 200A. Turns out that's the "3 minute" limit. Their "continuous" rating is 120A.

It supports running in reverse. Simply connect the 'reverse' to a switch, flip the switch, and the motor will run in reverse. Not too interesting for a two-wheeler but 3-4 wheelers would find this very helpful as otherwise running in reverse involves a "reversing contactor" or a reverse/forward switch external to the controller.

It appears to have regenerative braking. However they warn that regenerative braking is not enough, and that you should also have mechanical braking. Looking closely at their web site, they offer a PM controller or a PM controller with regeneration. The serial number has this coded, and the one I bought does not have regeneration.

http://www.kellycontroller.com

http://www.kellycontroller.com

http://www.kellycontroller.com

http://www.kellycontroller.com

http://www.kellycontroller.com

http://www.kellycontroller.com

http://www.kellycontroller.com

racermike39
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Re: Kelly Controls first impression

Hey Dave. I enjoy reading your posts and following the progress of your projects.

I thought I would chime in on this one, as I just completed my conversion of a four wheeler, using a Kelly Controls 200A controller.

I contacted Kelly directly, and inquired about ordering the correct controller for my motor. I have a used Elec-Trak field wound, seperately excited 36V motor. They recommended a particular controller and I ordered it. Well It did not work on the first try, and from the beginning Kelly said they would be willing to help develop a controller that would work with this motor. I contacted them, and they worked immediately on solving the problem. They e-mailed programs for me to down load, and settings to try. After about a week, they sent me a tracking number and informed me a new controller was on the way with a modified field current and modified field saturation setting. The second controller arrived in 3 days. I plugged it in and it worked right out of the box.

So my first impression is excellent with Kelly. Their customer support was the greatest. The product seems to be very good. I took a risk with Kelly, as AllTrax has a controller already for this application. AllTrax was $399, Kelly was $229. Someone else is selling the AllTrax controller for the Elec-Trak for $600. It seems the risk was well worth it. I hope too soon see a large vehicle controller (144v) from Kelly. I am ready to convert a car, and I would order a Kelly Controller as my first choice.

I drilled the terminals out to accept a 1/4-20 bolt. I also drilled out the F1 & F2 terminals to 10-32.

Keep us posted on your experience.

Racermike
5 years ago I met Jesus and he total ruined my life. I have never been happier.

Alias
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Re: Kelly Controls first impression

Looking forward to checking out the new controller and seeing the elite up and running :)
Thank you for ordering it :)

racermike39
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Re: Kelly Controls first impression

Hey guys.

Just a point of information.
I ran into a funny situation Dec. 24th. We were playing around with the 4-wheeler we converted using a Kelly Controller. When we first went to use it, The controller would not pull in the contactor. I thought it was a low voltage problem, but as it turns out, the Kelly controller won't energize the motor below 20 degrees C. After checking the error code, I realized that it was just too darn cold out (about 5 degrees C). Kelly explains that this is designed to protect the battery pack in cold weather. I parked it in the sun for a few minutes, and everything was fine. If your controller gives you trouble after spending the night out in the cold, just warm it up a little.

We spent the next hour taking turns riding up and down the street to see how long the battery pack would last. With only a 36V 18AH battery pack, we rode it for almost an hour.

FYI.

Mike K.

Racermike
5 years ago I met Jesus and he total ruined my life. I have never been happier.

Efried
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Joined: Friday, December 14, 2007 - 08:28
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Re: Kelly Controls first impression

Hi,

I have some similar but more harmful experience.
since my charger blew up when used in foggy weather at some plus °C degrees, we have to warn the manufacturers:

electric vehicles will never appear in masses before they have solved their homework!

every day usability is not trivia with 200-600V either!

Efried

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