Kelly KLS controller – configuration

How to configure the Kelly KLS controller

Configuration applies to all Kelly KLS series controllers, regardless of the size or voltage of the controller.

Basic parameters for configuration
Kelly KLS controller

In order for the controller to work, the following fields must be configured in the program: 2 tabs.

  • Low Volt: Drive cut-off voltage with low battery
  • Over Volt: Cut-off voltage for drive and regenerative braking with an over-charged battery
  • Current Parcent: Phase current of the motor supply expressed as% of the maximum controller current
  • Battry Limit: The current drawn from the battery expressed in% of the set phase current
  • Identification Angle: Hall test: 85 = normal operation / 170 = Hall test after restarting the controller
  • TPS Type: Throttle type 1: 0-5V potentiometer, 2: Throttle with Hall sensor
  • Change Direction: Change the motor rotation direction forward / reverse if it spins in the wrong direction after the Hall test
  • Motor Poles: Number of pieces (not pairs) of magnets in the motor
  • Speed ​​Sensor Type: Rotor position sensors: enter 2 type: Hall sensors

First run procedure
and pairing the motor with the controller

Changes in the Vehicle tab:
1. Set the operating voltage of the controller min. max .:
For the „Low Volt” field: enter: 3.0 V * number of sections in the battery and „Over Volt”: enter (4.2 V * number of sections in the battery) + 2.0 V
For example:

„Low Volt”: 39 V
„Over Volt”: 57 V

„Low Volt”: 48 V
„Over Volt”: 69 V

„Low Volt”: 60 V
„Over Volt”: 86 V

2. Pre-limit the driver currents to 30%: „Current Percent” and „Battry Limit”.
3. Set the throttle type to 2 (for a Hall sensor based throttle – most ebikes): „TPS Type”.
4. Set the „Identification Angle” parameter to 170 – this will force the Hall test to run after restarting the controller.

Changes in the Motor tab:
5. Set the parameter: „Motor Poles” – enter the number of magnets (not pairs).
6. Set the parameter: „Sensor type” – enter 2 for Hall sensors.

Halli test / pairing the controller with the motor:
7. Press the buttons: „Write”, „OK”, „Quit”.
8. Disconnect the USB cable.
9. Restart the bike / controller.
10. Wait for the Hall test to be performed, the wheel will spin very slowly, and finally the red LED will start flashing with the code 3,2 internal reset – it means it’s ok and the Halli test is over.
11. Restart the bike / controller.
12. Activate the throttle gently and check the direction of wheel rotation.
13. If necessary, connect to the program and change the direction of the wheel rotation / change the „checkbox” – „Change dir”. Press: „Write” button and restart the controller.
14. Carry out a road test.
15. Increase the „Current Percent” and „Battry Limit” currents („Vehicle” tab) as desired and needed.
16. If necessary, configure the remaining configuration parameters.

How to improve and enrich the action
of Kelly KLS controller?

The Kelly KLS controller in terms of its small dimensions and very good performance (continuous current 50 A, temporary 120 A) is really worth recommending. Unfortunately, it is very limited in its functionality as it only has the option of connecting a throttle. It offers nothing more. Therefore, to this controller, you can add the MPe on-board computer, which, in addition to adding the PAS support (torque sensor and pedaling sensor), will give us a number of other possibilities, including:

  • remaining distance on battery
  • possibility to protect against overheating, e.g. of the battery or the motor (with the drive cut-off function)
  • limiting the power of the throttle
  • pedaling assist power limit settings (full freedom – e.g. 250 W)
  • cruise control
  • and many others

We appreciate the addition of a pedaling torque sensor. Driving with this computer is very comfortable, safe and fun, and even improves your condition 🙂.

The entire MPe offer can be seen on the website about this device:

If you have questions, ask them in the comment at the bottom of the article.

Why an electric bike?

Why an electric bike?

Find out 10 reasons
why it is good to have an electric bike.

One thing is certain: ebikes become very popular today and appear more and more often on our roads.
Why do we choose an electric bike? I will present my and Marek’s reasons why we’ve decided to have an electric bike. They will be based on our history. Let’s get started:

Reason No. 1:
Let's get less tired

Electric assistance relieves us. And that was the reason number 1 why Marek chose an electric bike:

„I just don’t like to get tired.” 😉

Reason No. 2:
We can get much further

For an out of shape cyclist, driving 20 km can be a challenge. I remember in 2015, when Marek and I went on a trip. Back then, we were still riding ordinary bikes, without electric assistance. We were supposed to drive about 30 km. For me, an amateur cyclist, it was easy, and for Marek it was a test of fitness. Well, we finally did 50 km and Marek was very tired😜.

Today, on an ebike, we even 100 km. Our butts hurts, but the condition is no problem.

Reason No. 3:
We're cycling faster

Driving up to 50 km/h (and more) is possible with an electric bike. However, we should remember about our own and others safety. And always wear a helmet, even at 15 km/h.

We always ride in a bicycle helmet
We always ride in a bicycle helmet

Reason No. 4:
Driving upwind is not a problem

The wind is a challenge - not for ebike
The wind is a challenge - not for ebike

„I’m not going today, it’s windy.”

While driving with the wind is great, going against the wind is a challenge. We turn on the electric assistance and we do not get tired.

Reason No. 5:
Electric bike
it's a cheap mean of transport

What is the cost of riding an electric bike?

  • (0,25$ for battery charging per 150 km).There is no more to say.

Reason No. 6:
We take care of our physical health

While riding a bike (even an electric bike), we strengthen:

  • calves
  • thighs
  • buttocks
  • stomach
  • hands
  • neck
You need strength to ride a bike
You need strength to ride a bike

Also on an electric bike it is possible to get tired physically and we often decide how much we want it.

Reason No. 7:
We take care of our mental health

Electric bike and endorphins
Electric bike and endorphins

When cycling, endorphins are produced, which means well-being and contentment 😀

Reason No. 8:
Ebike for disable people
(heart defects, motor disability)

Electric Tricycles with MPe computer
Electric Tricycles with MPe computer

There are many people who, unfortunately, cannot afford to ride a bicycle physically. Heart disease does not allow you to exercise. Turning on the electric assistance can relieve us or we can also use a throttle.

Reason No. 9:
Anyone can build electric bike

„Building an ebike is so hard and complicated.”
„I don’t have a workshop or tools to build an electric bike.”

We know these statements. We thought the same when we wanted to build our first ebike ourselves.

„Where to start, what drive and bike to choose? Can my bike be converted into an electric one? “

And although we encountered many problems on the way in building an electric bike, we know today that it does not have to be that difficult. Today knowledge is common on the internet and you can find a lot of information. It is enough to want and reach for knowledge.

Lithium-ion battery pads
Lithium-ion battery pads

Often times, electric bikes are built in the center of the room. You don’t really need complicated tools.

Reason No. 10:
Ebike as a new hobby

Mark from the Bikel.pl company / eBIKE COURSE - lesson 8 - about HUB motor
Mark from the Bikel.pl company / eBIKE COURSE - lesson 8 - about HUB motor

The very fact of riding an electric bike can be a new life idea for us. We know it together with Marek and we spend every possible moment together, visiting and getting to know new places, as well as new people. 😊: Taba na rowerze). 

Electric bike -
definitely on

YES

Electric bikes are our passion, spending time together and developing – our company Bikel.pl 😉.

We want to wish you such a passion.

Or maybe you have other arguments why an electric bike? Let me know in the comments.

Bikel.pl crew

Construction cost of e-bike with MPe

CONSTRUCTION COST OF e-BIKE with MPE

How much does it cost to build an electric bike?

The cost range of building an electric bike is really wide. Prices can fluctuate here, even from 144 Euro / 160$ to over 7300 Euro / 8000 $.

In this article, you will find out the cost we incurred to build our „Minion” e-bike.

Price of e-bike with MPe computer

We will show here 2 price options for building an electric bike, taking into account the MPe computer set with different displays:

  • MPe (90A) computer with a small MiniOled display
Construction cost of e-bike with MPe computer and MiniOled display
Construction cost of e-bike with MPe computer and MiniOled display
  • MPe (90A) computer with large MaxiColor 850C display
Construction cost of e-bike with MPe computer and MaxiColor 850C display
Construction cost of e-bike with MPe computer and MaxiColor 850C display

Performance and possibility

Now it’s time to take a look at what our e-bike “can”:

  • Vehicle weight 28.5 kg. This is a pretty low result for an electric bike.
  • The 16S7P battery (1100Wh, LGMJ1 cells) will allow you to travel approx. 70 – 100 km (smooth ride up to max. 30 km / h, relatively flat terrain).
  • Top speed: 54 km/h.
  • Acceleration 0-40 km/h: 5.5s (test performed on the GT 1500, 45A controller)
  • Maximum power (indications from MPe computer): 2400W
  • Quiet operation of the Sabvoton Mini SVMC072045 45A controller. Initially, we had a GT 1500 45A square wave controller for a long time, which is much cheaper than the Sabvoton. However, the GT 1500 has several drawbacks. You can read about why the decision to change the controller was made. Read: HERE
  • The construction of the electronics box cost a lot of nerves, not to mention time. Read: HERE
  • The Kellys Madman 50 L, 21 frame is in our opinion quite large, even at a height of 180 cm. In the field, sometimes a slightly smaller frame (M, 19 ′) would be “more comfortable”.
  • Wheel / tire size: 27.5 ″ / 2.2
  • This bike certainly lacks full suspension. Although the NCX suspension seatpost is much more comfortable to ride than without it. We recommend this solution for every bicycle without rear suspension. It perfectly absorbs bumps on the road (by buying from the source below you support our business without losing any penny – the so-called affiliate link).

Extra possibilities for an electric bike -

MPe computer

Above you can see the cost of converting it into an electric bike of this class. The Minion is additionally equipped with an MPe computer, which gives it many unique possibilities. Today we CANNOT IMAGINE driving without this MPe computer.

Features of the MPe computer give us a number of capabilities
Lots of possibilities for an electric bike - MPe computer

Computer MPe price

in relation to the total cost of building an e-bike

Building an electric bike can bring great satisfaction. Especially when the bike starts to work and assist us. It is also often not a small expense, but do you have to have everything at once? We often buy, e.g. a controller, frame, battery pack, and then replace it with another, stronger, bigger, better one. We want more watts, more power, more adrenaline. And changes are associated with further expenses. And so it goes on:

we put aside money 🐷(new ideas)

collect savings 💲

and finally we make a PURCHASE and we have a PRIZE 🚲 (e.g. MPe computer)

And it is beautiful because there are more opportunities to make our dreams come true. And after all, riding an electric bike is a beautiful passion, but also a hobby that allows you to build a great vehicle.

You have to decide for yurself what do you want to spend your saved money on. And we are happy that more and more people decide to buy an MPe computer. As of today, there are over 200 sets of MPe computers that have been delivered to our customers, not only in Poland, but also in the Netherlands, Germany, Switzerland and France. We are grateful to you, thank you for your trust and such a big, positive response.

Comments

If you want to show yourself how much it cost you to build an electric bike, write about it in the comment at the bottom of the article. We are curious.

And stay up to date 😎:

FB group e-BIKEL-owcy technically about electric vehicles

FB group „e-BIKEL-owcy"

In the Facebook group we exchange experiences and comments on electric vehicles

Sabvoton MINI controller

Sabvoton MINI controller

SVMC072045

Where did this decision to change the driver came from?

The Sabvoton MINI controller is a new solution for our electric bike. Until now, it was driven by the GT1500 45A square wave unit. Everything was OK and there was no lack of power, but still that square wave sound …

GT1500 controller in Minion electronics box
GT1500 controller in Minion electronics box

I was thinking about KT sine wave 60V 45A, but I gave it up becouse of its gigantic size (255x85x45). The box has space calculated on the GT1500 and nothing bigger will get in.
The dimensions of the GT1500 controller are 180x87x43 [mm] (without cables and eyelets for screwing).

Later I got the Sabvoton MINI controller (SVMC072045 72V 45A). Unfortunately, it also turned out to be too big (too high). Out of curiosity, however, I dissassembled this Sabvoton MINI and it turned out that half the volume inside is air. That’s why I decided to take a risk and change the housing in it.

Controller dimensions: left: GT1500, middle: original Sabvoton MINI housing, right: Sabvoton MINI without electronics box
Controller dimensions: left: GT1500, middle: original Sabvoton MINI housing, right: Sabvoton MINI without electronics box

Let's go!

New housing for the Sabvoton MINI

This Sabvoton MINI controller has mosfets bolted to a thick aluminum plate, which I decided to use as one of the housing walls. Thanks to this, there was no need for so much 3D printing, and additionally there is better cooling of the controller. The USB port for programming is now built into the wall of the device.

Here you can download the files for printing the 3D housing:

Podczas pracy na obudową sabvotona mini

The new dimensions of the Sabvoton MINI are: 119x89x53 [mm] (without cables). It’s like cutting a KT sine of 45A by half 😉.

  • All gaps and joints of the new housing were sealed with E8000 silicone adhesive.
  • I also threw the “Silica gel” granulate inside the housing so that it absorbs moisture.
  • I threw out the control cables from the controller that I don’t use.
  • In addition, I added the LM35 temperature sensor to it to monitor it on the MPe computer.

It fits "like a glove" 😊

The whole procedure turned out to be a shot in a bull’s eye 🎯. The driver easily fit into the Minionek’s box, and finally it took up less space than the GT1500 initially.

New Sabvoton MINI housing in an electronics box
New Sabvoton MINI housing in an electronics box

First driving test

The first tests show that the controller works perfectly and does not overheat in this application. It is set to 40A of battery current, and the MPe computer counts the maximum actual current consumption of 50A. The phase currents are set: Rated: 150A, Max: 180A, Protected 230A.

When I was driving 100 meters up a steep hill, the power was always at 48-49A. After a few such climbs, the engine heated up to 130 ° C, and the controller only to 50 ° C.

The battery in the Minionek is 16S and on a fully charged battery with the Nine Continent 7×9 engine it accelerates to about 50 km / h (with the Flux 25A).

It looks like this Sabvoton MINI SVMC072045 will stay with Minionek for longer 😎.

Stay tuned:

FB group e-BIKEL-owcy technically about electric vehicles

Group e-BIKEK-owcy

In the Facebook group we exchange experiences and comments on electric vehicles

Construction of an electronics box

Construction of an electronics box

BAG OR BOX?

IS IT WORTH GOING TO EASY?

If not the most difficult, then certainly the most labor-intensive stage when assembling an electric bicycle is the construction of a battery and electronics box. Of course, you can go easy, like I did in my first project, and use a textile bag mounted in the triangle of the bicycle frame. At first glance, this seems like a cool and aesthetic solution. Unfortunately, realities quickly verify the idea as good only for a moment. While it looks really neat and does not arouse much interest in bystanders, it turns out that such a bag has, unfortunately, several key disadvantages. The choice of solid bags is limited, and when we hit a nice model, we won’t fit too much into such a bag. In my case, the bag fits 78 cells of size 18650 (13S6P), 48V 18A controller, 5v power supply, cables and charging socket. I will not stuff more if I wanted to. This set weighs about 4 kg and this bag was certainly not designed for such a load. Once, I even managed to break the attachment strap when I drove into a larger hole on a dirt road. The most glaring fact for me is that the textile clamps fastening the bag to the frame and the bag itself at the point of contact with varnish can scratch all the paint into bare metal. At the end I leave the questionable watertightness of the bag itself in case of stronger rainfall.

I prefer solid box

In my subsequent projects it was certain that I would not use a textile bag anymore. I decided to make a box of polyester resin laminate and fiberglass mats. On thematic forums you can read a lot about how people make containers from this material. There are as many methods and formulas as there are makers. Most often, however, visually such boxes are very “heavy and rough” and I did not like them. I will not post pictures of boxes that I do not like, because their authors might feel offended, and it is not my goal to insult someone. I hope that everyone who reads my scribbles knows what I mean by writing “heavy and rough”.

I set a goal that my boxes must optically match the bicycle based on a regular frame. It is known that such a frame is made of pipes or more modern hydro-molded profiles. The cross-sections of such sections are max 50mm, and our box has the widest point around 130mm (you can’t do more because the cranks would hook the edges of the box). If I put in a nearly rectangular box, there would be a significant change in width around the frame tubes, which would not look good to me. Therefore, I decided to add bevels, running parallel to each of the tubes of the triangle of the frame. This solution, unfortunately, reduces the space inside the box, which we have to use for battery and electronics, but it fits much neatly with the entire bike. Practice shows that despite the reduced capacity of the box, you can easily stuff the 45A controller and about 1200Wh battery, which in an e-bike design based on a classic frame is sufficient to cover a distance of about 100km.

Let's go design!

Therefore, I have assumptions, it’s time to begin the project that will be supported by 3D CAD software.

1. I start by measuring the arms of the triangle formed by the frame. At this stage, you can help by cutting out a cardboard template, fitted to the frame and measuring its sides. I measure the dimensions inside the frame.

2. From the middle of the frame, I take a photo of the whole bike, which I then place in the software. Using measurements and photo as a background I created the rest of the project.

3. At the moment, I am mainly guided by visual aspects and I try to do everything to make it as pleasant as possible. I try to remember to leave about 10mm of space around the container, so as not to bother with its subsequent installation. At the first design of the laminated box – for “Pienius bike”, unfortunately I left too little space and I had a problem with the seal connecting both halves. Under the upper tube, the derailleur cables and the brake hose run and are almost in contact with the box. In the second design of the resin container for “Minion bike” I have already corrected it.

4. When theoretically everything looks OK, I proceed to check what I can fit into the modeled box. At this stage, you can still make small adjustments to the project, which can result in adding the additional battery section in or take one out.

Time to roll up your sleeves 🙂

Method one

1. Okay, the battery and controller are in the box, it’s time to finish the project and start construction. Theoretically, I made both boxes using the same method – by laminating. However, the devil is in the details. The „Pienius bike” box was made first and then I came up with the idea that I would make the mold based on inside dimensions for it, and after thar i will stick everything with resin and fiberglass mat. I did a template made of cardboard and adhesive tape. Such 3D PUZZLE.

Horror

2. I think the devil in its own person was sitting on both my shoulders and told me to follow this path. In so far as assembling the mold and laminating did not cause any major problems, but finishing this SHAPELESS THING (that looked like ham/gammon) that i laminated, required countless hours (at least 10 hours) and many sand papers for an orbital sander. After the this part, my garage was suitable for thorough cleaning. The foil I hung up to separate the dirty part from the rest did not help. Dust from grinding laminate settled everywhere, in every smallest, furthest, smallest corner of the room was a minimum half a millimeter layer of fine dust! Dust that you couldn’t just sweep away. Everything with Ania cleaned the next X hours and even the walls had to be wet cleaned … Anyway, see for yourself.

3. After initial sanding, I applied a layer of colored gelcoat to fill larger holes and sand again. Theoretically, this was to result in a navy blue substrate, however, I sanded a lot of it again, and I lost my nerve for the next layers of gelcoat.

4. After grinding, I halved the whole with a mini-grinder with a cutting disc. I tried to cut on a drawn line, but it is impossible to get two identical halves with this method. Fortunately, the whole is connected by a rubber gasket, which will mask the larger shortcomings of the cutting line. Somehow it all managed to bring order to order. After the first adjustments, it turned out that even it begins to fit.

5. In the workshop where I used to work, I managed to add some mounting plates to the box. Made of 1.5mm thick sheet metal with M5 welded nut and several spacers. Then I fixed it in the place for a water bottle. It takes a little bit of effort to adjust it all, but in the end it all worked out. While fitting the box to the bicycle frame, I roughly marked a point for holes, and then I first drill with a small drill d3, and then drilled to d6, taking care that the laminate did not tear. Then i adjusted the box on the mounting plates. At the top of the box I used a bracket printed on a 3D printer fitted to the bicycle frame.

6. It remains to fill the shortcomings that remained and paint in the target color. Unfortunately, I was not able to finish everything to high aesthetic level, my impatient nature won. It would be good to fill everything up twice, because after painting you can still see the irregularities of the laminate. However, I already wanted to put it all together so left it as it turned out. It’s time for ready assembly and adjustment of the rest of the equipment and for affixing the finishing labels of the whole design – laser cut from 1.5 mm thick aluminum sheet. I ordered colorful acrylic sprays and colorless matt lacquer at a popular auction site, choosing similar colors to the bicycle frame.

Time for the second method!

As they say “The first pancake is always spoiled”. Having learned all the hardships associated with laminating resin on the interior mold of the box for “Pieniuś bike”, I came to my senses.

1. I made the second box, this time for “Minion bike” by laminating the two halves separately (unfortunately I don’t have photos from the whole process …). Left and right forms, this time mapping the outer surfaces of the box, I also made of cardboard, of course, all previously modeling in CAD 3D. Corners with a radius I glued with pulp available in every shop with artistic products. I smoothed the exact radius in the cellulose mass with a disc, printed on a 3D printer, with a diameter corresponding to the corners.

2. This time sanding after lamination was just a cosmetic. In an hour I sanded both halves. In several places, you also had to use putty to level the surface on which there were cavities from air bubbles. The contact surface of the two halves was ground by sticking sheets of sandpaper on the table top and the whole half of the box was scrubbed on this surface with sandpaper. I consider such a laminating solution with a projection in the form of external planes to be recommended.

3. The box colors have also been chosen according to bicycle frame and ordered acrylic sprays. In addition, I also bought a colorless spray with a structure effect that is painted first. It gives the entire surface a sandblasted structure. This eliminates the visual effects of laminate unevenness and the whole looks very aesthetically pleasing. Finally, all the electronics had to be adjusted to the inside of the container again, and finally secured everything with mounting foam.

It's good 😀

I consider the goal almost achieved. It looks good, houses the equipment that I need. The mounting foam holds all the components inside as it should, and thousands of kilometers after verses are not able to loosen anything. Such a box can be opened if necessary by unscrewing one half (it is best to rethink the arrangement of components in this regard). The only drawback is the problematic fitting of the two halves relative to each other – even on seals. It is difficult to press perfectly so that there is a tight connection. Unfortunately, there is a risk that in unfavorable weather conditions water will get into the box through not tight connections at the top of the box. To minimize this risk at the joint, on the gasket, I additionally stick black insulating tape.

Bicycles with such boxes look really great. I highly recommend this solution to everyone, as the final e-bike based on a regular frame, with powers up to 3kW and a range of about 100km. If someone needs more (range or power), then better go straight to the custom frame.

Pieniuś i Minion
PIENIUŚ left / MINION right

We have also third way!

30.08.2018 – we have and third way. But what I will describe, you just have to watch it. I say we have, because it was created with the participation of Radek, from the TABA ON BIKE channel. The largest electric ebike channel in Poland.

Stay tuned 😊 :

FB group e-BIKEL-owcy technically about electric vehicles

Group e-BIKEK-owcy

In the Facebook group we exchange experiences and comments on electric vehicles