ME1115 & Kelly KLS8080IPS commissioning problems

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SPanna
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Real Name: Sam

ME1115 & Kelly KLS8080IPS commissioning problems

Post by SPanna » Wed, 18 Jul 2018, 15:14

Hi all,
I am new to this forum and would like to introduce myself.
I am building an electric motorcycle utilising ME1115 motor, Kelly KLS8080-IPS controller, Headway 38120S cells 24S11p giving me 79V 110Ah capacity,using a ZEVA BMS & 1.8KW TC charger.

I am at motor testing stage & have struck problems with the controller, I have completed the identification angle operation as per manual & all is good when the rear wheel is off the ground.
As soon as I load up the motor it trips with a Hall Error fault.

I have been in discussions with fany at Kelly but it looks like they don't know what to tell me next.
Has anyone had experience similar to me regarding drive trips?
Help greatly appreciated.

Sam

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Richo
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Real Name: Richard
Location: Perth, WA

Re: ME1115 & Kelly KLS8080IPS commissioning problems

Post by Richo » Fri, 20 Jul 2018, 12:59

Ah that sounds like a nice setup.

Speed sensor type: 4 Line Hall
Line Hall Zero: 0-1023-> 0-5V check with mars what "practical" value is.
Line Hall Amplitue:0-1023-> 0-5V maths reqd
Line Hall High Err: ***Probable cause*** 0-1023 -> 0-5V [try increase this value]
Line hall low err: as above

Also as a side note:
Motor Nominal curr: suggested to increase if have a high power motor


So my guess is "Line Hall High Err" is not high enough.
Help prevent road rage - get outta my way! Blasphemy is a swear word. Magnetic North is a south Pole.

SPanna
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Joined: Wed, 18 Jul 2018, 15:04
Real Name: Sam

Re: ME1115 & Kelly KLS8080IPS commissioning problems

Post by SPanna » Tue, 24 Jul 2018, 12:25

Thanks for your input Richo.
Unfortunately had no luck with the Amplitude / Zero crossing path.
After many emails with Fany at Kelly ctls and using their SinCos monitoring program I have tried many different variation of the correct values for these parameters under Kelly advisement.
They have also provided me with new firmware which spits out 2 more monitoring variables. Apparently the Hall Err alarm is not just triggered by Line Hall low / high values we can enter.
We have tried setting these to min / max limits & monitored value under load, the alarm is definitely not triggered by Low/High setpoints.
I believe the lack of torque under load is the root cause and as the controller sees inadequate value change from SinCos sensor it triggers the alarm.
Still waiting to hear back from Kelly as to what to do next.

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Richo
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Real Name: Richard
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Re: ME1115 & Kelly KLS8080IPS commissioning problems

Post by Richo » Wed, 25 Jul 2018, 12:29

That sounds frustrating.
If it was me I'd try throwing some spanners and cursing at it.

Has Kelly told you ALL the conditions that can trigger the hall error?
Did you try adjusting the motor nominal current up say 10%?

The other thing is it could be electrical noise on the hall line.
Have you wired the hall wires next to the phase power wires?
When you load up the motor the current will be higher than free spinning in the air.
This extra current could induce noise in the sin/cos lines and trip the controller as it would see a spike.

A couple if pics would be nice.
Help prevent road rage - get outta my way! Blasphemy is a swear word. Magnetic North is a south Pole.

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