72V ONYX Kelly Parameters (What Changes Performance)

This page is part of the ONYX Performance Guide

Intro

This document captures the stock Kelly KLS7230S controller configuration used on the 72V ONYX. It preserves the exact factory parameter set exposed through the Kelly interface while documenting controller behavior that is not visible in standard Kelly configuration tools.

The intent is to provide a reliable baseline for diagnostics, comparison, and controlled tuning without altering the original data.

The stock configuration table preserves directly observed controller values. Additional firmware-dependent and non-exposed sections include example values or representative ranges where needed to explain how hidden parameters typically behave. These examples are not confirmed stock settings unless explicitly listed in the main configuration table.

Summary

• Full stock parameter set preserved without modification
• Control loop fields clarified to reflect actual controller architecture
• Firmware-dependent parameters and hidden behavior documented
• System behavior explained without altering configuration
• Suitable as a baseline reference for diagnostics, tuning comparison, and validation

System Overview

Stock Kelly Controller Settings

Checkbox values are transcribed as “Check Mark” (enabled) and “No Check Mark” (disabled). Blank fields indicate values not populated or not returned by the controller interface.

Some parameters may not appear in all versions of the Kelly controller interface. Visibility can vary depending on firmware version, software (Motormed / AC Aduser), and controller configuration. Missing fields in the UI do not indicate missing functionality.

This table lists the factory configuration for the Kelly KLS7230S controller used on the 72V ONYX.

This is a direct export of the controller configuration and is intentionally unmodified.

Fields are not grouped by function in the original interface and appear in the order provided by the controller firmware.

The table includes a mix of:

• user-adjustable tuning values
• calibration values derived from motor identification
• internal scaling and control loop parameters
• binary flags representing controller modes and logic states

Not all fields have equal impact on system behavior:

• some directly affect performance and ride feel
• some define system limits and protections
• others are calibration values that should not be changed without full system understanding

High-impact fields typically include current limits, throttle mapping, braking behavior, and speed limits.

Detailed explanations and functional grouping of these parameters are provided in the sections that follow.

Additional Firmware / Hidden Parameters (Reference Table)

This table is a reference index of firmware-dependent and non-exposed parameters that may exist across Kelly variants. Detailed behavior, example ranges, and interaction notes are documented in the sections that follow.

Parameter Risk Classification

The following risk classification is intended as a practical tuning guide for the parameters most likely to be adjusted or misadjusted.

Additional Parameters (Firmware Dependent)

This section lists firmware-dependent parameters that may exist on other Kelly variants but are not visible in this dataset.

The Kelly KLS7230S controller may expose additional parameters depending on firmware version, controller revision, and configuration software. These are not present in this dataset but may appear in other controller variants.

Their absence in the table does not indicate missing functionality.

These parameters are often controlled internally by firmware, may not be visible or adjustable through standard Kelly configuration tools, and follow the same system relationships defined above. They may also override or interact with user-visible settings in the main configuration table.

Field Weakening

These parameters control high-speed operation beyond the motor’s normal voltage-limited speed range.

• field weakening allows the motor to spin faster than its normal base speed at a given battery voltage
• it works by reducing effective magnetic field strength at higher RPM
• this increases top-end speed, but it does not create additional power

Behavior characteristics:

• low values produce a mild top-speed increase with less heat
• higher values can extend speed further, but current draw rises quickly
• torque drops off more noticeably as speed increases
• motor and controller temperature climb faster during sustained high-speed riding

Important:

• field weakening does not increase total power, only extends usable RPM range
• aggressive values can overheat the motor quickly
• excessive weakening can make the bike feel faster at the top end but weaker and less efficient under load
• real results depend heavily on battery voltage, gearing, motor characteristics, and load

Regenerative Braking Control

These fields determine how much regenerative current the controller is actually allowed to apply.

• these fields control how much braking force the controller can produce electrically
• unlike brake percentage settings, they act as current-based limits on how much regen can actually happen
• this is a primary factor in whether regen feels light, moderate, or very strong when the brake is applied

Behavior characteristics:

• lower values produce gentler deceleration and less battery charging current
• higher values increase braking force and make regen more noticeable
• aggressive settings can make the bike feel abrupt when braking begins
• regen is strongest at higher speed and naturally gets weaker as RPM drops

Important:

• these limits may override or reshape BRK_SW / BRK_AD percentage settings
• actual regen feel is usually a combination of brake percentage, regen current limits, and motor speed
• excessive values can increase battery stress, BMS intervention, and motor heat during repeated braking
• strong regen settings may feel good at speed but still taper off near low RPM because back EMF falls with speed

Torque and Speed Limits

These fields act as hard limits on what the controller is allowed to output.

• these parameters act as upper limits on what the controller is allowed to do
• they apply regardless of throttle position or rider input
• they sit above other settings like throttle mapping and current limits

Behavior characteristics:

• lower torque limits reduce acceleration and overall power feel
• increasing torque limits improves launch and responsiveness
• speed limits cap top speed even if the system has power to go faster
• aggressive limits can make the bike feel unrestricted but increase system stress

Important:

• these limits may override phase current and throttle mapping behavior
• setting torque too low can make the bike feel flat or unresponsive
• setting speed limits too low can prevent reaching expected top speed even with correct gearing and power
• these are often used for safety, battery protection, or drivetrain longevity

Voltage Compensation

These parameters control how the controller responds to battery voltage sag during load.

• these parameters adjust how aggressively the controller tries to maintain performance as voltage drops
• instead of letting power fall naturally with voltage, compensation increases current draw to hold output

Behavior characteristics:

• low compensation results in noticeable power drop as battery voltage sags
• higher compensation keeps acceleration and power more consistent under load
• aggressive settings increase current draw to maintain output
• system may feel strong even at lower battery voltage, but at the cost of efficiency

Important:

• higher compensation increases battery stress and heat
• interacts directly with Bat Current Limit and overall system power draw
• aggressive settings can increase voltage sag rather than reduce it under heavy load
• behavior depends heavily on battery condition, internal resistance, and discharge capability

Control Mode and Behavior Flags

These fields control the controller’s internal operating modes and logic behavior.

• these parameters control how the controller interprets inputs and applies output
• they change the overall behavior of throttle, braking, and direction handling
• unlike tuning values, these act more like system-level switches

Behavior characteristics:

• torque mode provides direct and predictable throttle response based on rider input
• speed mode attempts to maintain a target speed, which can feel less natural on a bike
• regen modes determine whether braking occurs on throttle release, brake input, or both
• direction protection prevents immediate reversal, reducing drivetrain shock

Important:

• typically firmware-controlled and not always exposed in user tools
• incorrect mode selection can make throttle response feel unnatural or unstable
• regen mode configuration can significantly change how the bike behaves when coasting or braking
• direction protection is critical for safety and preventing mechanical damage

Additional Parameters (Extended Firmware Variants)

This section covers parameter families that may be user-visible in some Kelly firmware branches, engineering tools, or controller revisions, but are not present in this dataset.

The Kelly KLS7230S controller may expose additional parameters in other firmware branches, engineering tools, or controller revisions. These are not present in this dataset but are consistent with behavior seen across Kelly KLS variants.

Their absence in the table does not indicate lack of functionality.

These fields may be user-visible in some firmware, hidden in others, or partially controlled through internal logic that sits on top of the exposed parameter set.

Regenerative Behavior (Extended)

These parameters extend regenerative braking behavior beyond the standard exposed brake percentage and timing fields.

• Brk_Speed Limit defines the minimum motor speed (RPM) at which regenerative braking becomes active
• below this RPM, regen is reduced or effectively disabled because back EMF is too low to push current into the battery
• this is the point where regen begins to engage and become usable
• Low Speed Regen Cutoff defines an additional region where regen may be further limited or tapered as speed approaches zero
• Regen Ramp Rate and Regen Current Slew Limit shape how quickly braking torque is applied and removed
• Regen Voltage Clamp limits regenerative current as battery voltage approaches overvoltage protection

Behavior characteristics:

• regen strength drops as speed approaches the Brk_Speed Limit threshold
• below ~100 RPM, braking typically transitions from electrical regen to primarily mechanical braking
• prevents unstable or jerky braking at very low speed
• smooths braking engagement and release
• prevents abrupt negative torque spikes
• reduces the chance of overvoltage faulting during high-speed deceleration

Important:

• may not appear in standard Kelly tools
• may override or reshape BRK_SW / BRK_AD behavior
• real regen feel is determined by both exposed settings and internal limits like Brk_Speed Limit

Thermal Management (Extended)

These parameters control how the controller reduces power as temperatures rise, before reaching full shutdown.

• High Temp Str C defines the temperature where the controller starts reducing output
• this is the point where power begins to get pulled back to prevent overheating
• on most systems, this occurs noticeably before the hard cutoff (High Temp Cut C = 170°C in this case)
• High Temp Weak % defines how aggressively power is reduced once thermal limiting starts
• lower values result in gradual power reduction, higher values cause faster and stronger derating
• Thermal Derating Slope, Thermal Foldback Gain, and Thermal Recovery Rate control how quickly power is reduced and how smoothly it returns after cooling

Behavior characteristics:

• power is reduced gradually before reaching the shutdown temperature
• under sustained load, output will continue to drop as temperature increases
• repeated hard acceleration or high-speed riding will trigger earlier and stronger derating
• power does not immediately return once temperatures drop; recovery is controlled and delayed
• depending on settings, the system may feel strong initially but fade quickly under continuous load

Important:

• not exposed in this dataset
• works together with High Temp Cut C (170°C) and High Temp Resume (150°C)
• High Temp Str C typically sits well below the cutoff to allow controlled derating instead of abrupt shutdown
• has a major impact on how much power the system can sustain over time
• this is one of the main reasons short bursts feel strong, but continuous riding feels weaker as heat builds

Torque and Speed Constraints (Extended)

These fields shape deeper torque and speed limits that are not always visible in the standard UI.

• these parameters shape how torque is delivered across the full speed range
• they control the transition from strong low-speed acceleration to limited high-speed output
• they operate on top of visible limits like Max Speed and Phase Current

Behavior characteristics:

• strong torque at low speed gradually fades as RPM increases
• prevents excessive current draw at high speed where efficiency drops
• smooths the transition into top-speed operation
• limits abrupt or unstable behavior near maximum speed
• affects how aggressively field weakening engages at higher RPM

Important:

• may appear only in certain firmware or controller variants
• may override visible speed or current settings even when those values appear unchanged
• top-speed behavior is often governed more by these parameters than by Max Speed alone
• overly aggressive limits can make the bike feel strong off the line but weak at speed
• overly loose limits can increase heat, instability, and system stress at high RPM

Sensor and Identification Extensions

These parameters control additional motor identification and commutation behavior beyond the visible sensor setup fields.

• these parameters control how the controller understands rotor position and aligns electrical output with the motor
• they refine timing, improve efficiency, and ensure correct commutation across all speeds
• they operate continuously in the background once the system is running

Behavior characteristics:

• correct values result in smooth operation and consistent torque delivery
• phase advance improves efficiency and reduces heating at higher speeds
• improper alignment can cause rough operation, noise, or reduced performance
• identification routines ensure the controller matches the specific motor characteristics

Important:

• may be partially exposed only through engineering or OEM tools
• directly tied to motor identification success and sensor configuration
• incorrect hall sequence or phase alignment can prevent operation or trigger faults
• errors in this layer often appear as hard faults or startup failure rather than simple tuning issues

Voltage and Startup Management (Extended)

These parameters control higher-level power and startup management behavior.

• these parameters control how the controller reacts to unstable or changing battery voltage
• they also manage how the controller safely powers on and connects to the battery
• they operate continuously during both startup and riding conditions

Behavior characteristics:

• smooths power delivery during voltage sag or heavy load
• reduces sudden drops or spikes in output caused by battery instability
• prevents damaging current spikes during controller startup
• affects how quickly the controller responds to voltage changes under load

Important:

• may be hidden in standard user tools
• directly interacts with Low Volt, Over Volt, and Bat Current Limit
• aggressive current limiting can make the bike feel weak under load
• insufficient filtering or delay can cause harsh startup behavior or fault conditions
• startup reliability and consistency are heavily influenced by these parameters

Reverse and Direction Control (Extended)

These parameters control additional reverse and direction change behavior.

• these parameters control how the system behaves when switching between forward and reverse
• they are primarily designed to protect the drivetrain and improve rideability
• they operate automatically whenever a direction change is requested

Behavior characteristics:

• reverse power is usually reduced to prevent abrupt or unsafe movement
• reverse speed is limited compared to forward operation
• direction changes are delayed to allow the motor to slow down before reversing
• prevents sudden torque reversal that can stress mechanical components

Important:

• may be hidden even when Change Dir is exposed in the main settings
• intended primarily for safety and hardware protection
• aggressive or disabled limits can cause harsh or damaging direction changes
• overly restrictive values can make reverse feel weak or unresponsive
• timing behavior can make direction changes feel delayed if not understood

Internal / Non-Exposed Control Parameters

This section covers runtime behaviors and internal control variables that are generally not user-exposed.

These parameters are internal to controller firmware and are not user-configurable through standard Kelly tools. They may exist as stored calibration values, computed internal limits, diagnostic states, or runtime control variables.

They are included here to explain behavior that is real but not directly adjustable from the stock interface.

Control Loop Internals

These parameters define internal control loop behavior beyond the exposed IQ / IK gains.

• these parameters shape how quickly and smoothly the controller reacts to throttle and load changes
• they sit underneath the visible PID values and determine how those values are actually applied
• they are part of the controller’s internal FOC (field-oriented control) system

Behavior characteristics:

• stronger filtering results in smoother but slower throttle response
• faster slew rates make the system feel more responsive but can increase harshness
• saturation and clamp limits prevent unstable or excessive output requests
• observer and decoupling parameters improve accuracy and stability of motor control

Important:

• not user accessible in standard tools
• tightly coupled to internal firmware and motor model
• incorrect tuning would result in oscillation, instability, or inconsistent throttle response
• issues in this layer often feel like “bad tuning” even when visible PID values appear correct

PWM and Switching Behavior

These parameters control internal switching timing behavior of the inverter.

• these parameters control how the controller drives the power transistors (MOSFETs)
• they operate at the hardware level and directly affect efficiency, heat, and waveform quality
• they are critical for safe and stable inverter operation

Behavior characteristics:

• proper deadtime prevents shoot-through (both transistors conducting at once)
• too much deadtime reduces efficiency and distorts current waveforms
• deadtime compensation helps recover lost performance caused by switching delays
• switching behavior affects low-speed smoothness and audible motor noise

Important:

• not exposed in standard configuration tools
• required for safe operation of the controller hardware
• incorrect values would cause excess heat, reduced efficiency, or potential hardware failure
• this layer directly influences how smooth or “clean” the motor feels at low throttle

Thermal Modeling

These parameters define the internal thermal model used by firmware.

• these parameters estimate internal temperatures that are not directly measured by external sensors
• they allow the controller to reduce power before actual hardware limits are exceeded
• they work continuously in the background during operation

Behavior characteristics:

• power can be reduced before the controller feels hot externally
• repeated acceleration or sustained load will trigger thermal foldback faster than expected
• aggressive foldback settings reduce power quickly to protect hardware
• recovery is not immediate; power returns gradually even after temperatures drop
• the system may feel inconsistent if heat builds up faster than it dissipates

Important:

• not directly visible or adjustable in standard tools
• works alongside High Temp Cut C and High Temp Resume
• explains why thermal limiting can occur before reaching visible temperature thresholds
• one of the main reasons sustained riding performance drops compared to short bursts
• heavily influenced by cooling, airflow, and ambient temperature

Motor Identification and Commutation

These parameters define internal motor identification, rotor tracking, and commutation behavior.

• these parameters control how the controller determines rotor position and applies phase current
• they ensure correct timing between electrical output and mechanical rotation
• they operate continuously once the motor is running

Behavior characteristics:

• correct identification results in smooth startup and consistent torque delivery
• phase advance improves efficiency and reduces heating at higher speeds
• incorrect alignment can cause rough operation, noise, or reduced power
• ID Err will prevent normal operation if the controller cannot determine rotor position

Important:

• ID Err is a diagnostic condition, not a tunable parameter
• directly related to Motor Identity En and sensor configuration
• incorrect hall wiring, phase order, or resolver setup commonly triggers identification failure
• issues in this layer often appear as hard faults rather than tuning problems
• proper identification is required before any other tuning changes will behave correctly

Protection and Fault Handling

These parameters define internal protection behavior that limits damage and manages recovery after abnormal conditions.

• these parameters protect the motor, controller, and battery from unsafe operating conditions
• they monitor for stall, slip, voltage faults, and internal errors
• they automatically intervene when conditions exceed safe limits

Behavior characteristics:

• stall conditions trigger current limiting or shutdown to prevent damage
• slip detection can reduce power when expected motion does not match actual response
• regen may be reduced or disabled to prevent overvoltage during braking
• faults can either clear automatically or require a full power cycle depending on configuration
• watchdog behavior ensures the controller does not continue operating if firmware fails

Important:

• not user configurable in standard tools
• essential for hardware protection and system safety
• many “random” shutdowns are controlled protective responses from this layer
• aggressive riding or tuning can trigger these protections more frequently
• understanding these behaviors helps distinguish real faults from normal protection events

Startup and Alignment

These parameters define low-speed and startup behavior before normal closed-loop motion is established.

• these parameters control how the controller behaves at zero RPM and during initial movement
• they ensure the controller knows the rotor position before applying full torque
• they bridge the gap between a stationary motor and normal operation

Behavior characteristics:

• startup boost improves initial launch and prevents hesitation from a stop
• alignment current holds the rotor briefly to establish a known position
• longer alignment time improves reliability but can feel slightly delayed
• zero speed detection ensures stable transition from stopped to moving
• neutral current clamp prevents unintended movement when no throttle is applied

Important:

• not exposed in standard user tools
• strongly affects how smooth or abrupt the bike feels at takeoff
• improper behavior here can feel like hesitation, jerking, or delayed response at low speed
• startup feel is often determined more by these parameters than throttle mapping alone
• especially critical for systems that feel inconsistent only at very low speed or from a dead stop

Voltage and Power Management

These fields control how the controller manages battery voltage, power delivery, and startup sequencing.

• these parameters control how the controller reacts to voltage sag, ripple, and unstable input conditions
• they also manage safe startup behavior when the controller first connects to the battery
• they operate continuously during both startup and normal riding

Behavior characteristics:

• voltage filtering smooths out rapid fluctuations from the battery under load
• shorter averaging windows make the system more responsive but less stable
• longer averaging windows make the system smoother but slower to react
• dynamic current limiting reduces power when voltage drops to prevent damage
• power limiting curves shape how performance changes as battery voltage decreases

Important:

• not exposed in standard user tools
• directly interacts with Controller Volt, Low Volt, Over Volt, and Bat Current Limit
• aggressive current limiting can make the bike feel weak under load
• insufficient filtering can cause unstable or inconsistent power delivery
• startup reliability and smooth engagement are heavily influenced by precharge and delay timing

Signal Conditioning and Sensors

These parameters define sensor validation, filtering, and fallback behavior.

• these parameters control how the controller interprets and trusts position feedback signals
• they filter noise, reject invalid signals, and detect when sensors fail
• they determine whether the controller continues operating or shuts down when signal quality drops

Behavior characteristics:

• debounce filtering prevents erratic behavior from noisy signals
• timeouts define how quickly the controller reacts to missing or unstable sensor input
• higher thresholds increase stability but may reject borderline signals
• sensorless fallback can allow continued operation if a sensor fails
• poor signal conditioning can cause jerky motion, misfires, or sudden cutouts

Important:

• not exposed in standard user tools
• critical for reliable operation in electrically noisy environments
• incorrect thresholds can either hide real problems or trigger false faults
• many intermittent issues are caused by signal quality, not hardware failure
• understanding this layer helps diagnose problems that appear random or inconsistent

Input and Logic Handling

These fields govern how the controller validates inputs and enforces safe operating conditions.

• these parameters control how the controller interprets rider inputs and system signals
• they ensure that invalid or conflicting inputs do not result in unsafe behavior
• they manage how the controller reacts to communication loss or unexpected input states

Behavior characteristics:

• throttle plausibility prevents unintended acceleration from faulty signals
• brake override can cut throttle when braking is applied
• direction timers prevent harsh or unsafe reversal under load
• communication timeouts trigger fallback behavior when signals are lost
• fallback modes determine whether the system coasts, reduces power, or shuts down

Important:

• not visible in standard user tools
• critical for safety and system reliability
• can make a working controller appear unresponsive if inputs are invalid
• many “no throttle” issues are caused by logic conditions, not hardware failure
• understanding this layer is key to diagnosing situations where the controller ignores input

Parameter Behavior and Relationships

This section explains how the observed stock parameters interact in practice.

These parameters do not operate independently. Most values interact within control systems, and behavior should be evaluated based on combined effects rather than individual fields.

Voltage and Protection Limits

• Controller Volt
• Low Volt
• Over Volt

These parameters define the operating voltage window of the controller.

• Controller Volt defines nominal system voltage used for internal scaling and protection calculations
• Low Volt controls cutoff behavior under battery sag
• Over Volt defines maximum allowable input before shutdown

Current and Power Control

• Current Percent
• Bat Current Limit
• Phase Curr Max AD
• Motor Normal Curr
• Motor Identity En

These parameters define how power is drawn from the battery and delivered to the motor.

• battery current controls total system power and battery stress
• phase current controls torque production
• motor current defines sustained operating limits

Motor Normal Curr is the controller’s continuous motor current reference and relates to sustained output behavior and protection thresholds.

Motor Identity En is associated with motor identification and calibration behavior used by the controller to align internal control with the connected motor.

Current and Power Tuning Reference

Behavior examples:

• Increasing Bat Current Limit (55 → 100)

  • increases total power output
  • increases battery sag and heat
  • directly impacts range and battery stress

• Increasing Phase Curr Max AD

  • increases launch torque significantly
  • improves acceleration without proportional battery load
  • increases motor heating under load

Throttle Input Mapping

• TPS Low
• TPS High
• TPS Type
• TPS Dead Low
• TPS Dead High
• TPS Forw MAP
• TPS Rev MAP
• Accel Time
• Accel Release Time

These parameters define how throttle input is interpreted and translated into torque demand.

• TPS range defines usable throttle span
• dead zones prevent unintended activation
• mapping values shape response curve
• acceleration timing values control how quickly requested power is applied and removed

Accel Time affects throttle ramp-in behavior.

Accel Release Time affects throttle ramp-out behavior.

Throttle Tuning Reference

Behavior examples:

• Lowering TPS Dead Low

  • increases sensitivity at initial throttle
  • can make low-speed control more abrupt

• Increasing TPS Forw MAP

  • delivers torque earlier in throttle travel
  • increases responsiveness

• Lowering Accel Time

  • makes throttle response feel sharper
  • can increase abruptness during launch

Speed Limiting System

• Max Output Fre
• Max Speed
• Max Forw Speed%
• Max Rev Speed%
• MidSpeed Forw Speed
• MidSpeed Rev Speed
• LowSpeed Forw Speed
• LowSpeed Rev Speed
• Three Speed
• PWM Frequency
• Motor Poles

These parameters define how speed is limited across operating modes.

• percentage limits scale maximum speed
• three-speed settings define mode behavior
• Max Speed defines a configured RPM ceiling

Max Output Fre defines the maximum electrical frequency output to the motor and indirectly limits achievable motor speed based on pole count.

Actual motor RPM is determined by electrical frequency (Max Output Fre), motor pole count, configured limits such as Max Speed, and real load conditions.

PWM Frequency defines controller switching frequency and can affect smoothness, audible noise, and controller heat behavior.

Speed Limiting Tuning Reference

Braking and Regenerative Behavior

• BRK_SW Brk %
• BRK_AD Brk %
• RLS_TPS Brk Per%
• NTL Brk Per%
• Brake Type
• Brake Dead Low
• Brake Dead High
• Brake Time
• Brake Release Time
• Brake SW Level
• Change Dir Brk %
• IVT BRK Max
• IVT BRK Min
• Anti Theft Curr#

These parameters define how braking input is converted into regenerative or braking force.

• multiple inputs are blended internally
• timing values control ramp behavior
• dead zones define activation thresholds
• switch level settings define how digital brake input is interpreted

Change Dir Brk % defines braking applied during direction changes.

IVT BRK Max and IVT BRK Min appear to define internal braking limits or thresholds and may be firmware-dependent in behavior.

Anti Theft Curr# defines current behavior associated with anti-theft operation.

Regenerative Braking Tuning Reference

Behavior examples:

• Increasing BRK_SW Brk % (25 → 50)

  • increases regenerative braking force
  • reduces reliance on mechanical brakes
  • increases motor heat under repeated braking

• Increasing RLS_TPS Brk Per%

  • adds deceleration when releasing throttle
  • can reduce coasting behavior

• Lowering Brake Time

  • makes braking response engage faster
  • can feel more abrupt at low speed

Compensation and Stability Control

• Compensation Per%
• Torque Speed KP
• Torque Speed KI
• Speed Err Limit

These parameters define how the controller compensates for load changes and manages speed-related response.

Compensation Per% appears to control output compensation behavior under changing load or voltage conditions.

Torque Speed KP and Torque Speed KI define a separate speed-related control loop used to manage response under changing torque demand.

Speed Err Limit defines the allowable speed error used by the controller before corrective behavior becomes more aggressive.

These values affect how stable or forceful the controller feels under load but are typically best left near proven settings unless behavior problems are being diagnosed.

Control Loops (PID)

• IQ Kp
• IQ Ki
• IQ Kp (second field)
• IK Ki

These values define the controller’s internal feedback systems.

• inner loop regulates motor current (Iq / Id)
• outer loop controls torque demand and speed response

This mapping between exposed gain fields and internal control loops is inferred based on standard FOC architecture and observed behavior.

These values are typically pre-tuned and should not be adjusted unless instability is observed.

Improper tuning can cause oscillation, instability, or delayed response.

Control Loop Tuning Reference

Thermal Protection

• High Temp Cut C
• High Temp Resume
• Motor Temp Sensor

These parameters define thermal protection behavior.

• High Temp Cut C defines shutdown threshold
• High Temp Resume defines recovery threshold
• Motor Temp Sensor defines sensor type used for thermal monitoring

Behavior characteristics:

• once cut temperature is reached, controller output is reduced or disabled
• system will not resume full operation until temperature drops below resume threshold
• repeated thermal cycling reduces sustained performance
• thermal limits are often reached faster at sustained high speed than during short acceleration bursts

Important:

• thermal limits are the true continuous power constraint
• aggressive tuning will reach these limits faster
• cooling and airflow directly affect performance sustainability

Sensor Configuration

• Hall Galvan Rate
• Line Hall Zero
• Line Hall Amplitude
• Line Hall High Err
• Line Hall Low Err
• Resolver Start Angle
• Speed Sensor Type
• Resolver Poles
• Exchange Phase AB
• 0° Hall
• 60° Hall
• 120° Hall
• 180° Hall
• 240° Hall
• 300° Hall
• Forw A Rise Hall
• Forw A Fall Hall
• Rev A Rise Hall
• Rev A Fall Hall

These values define motor position sensing and commutation mapping.

These values align controller output with motor position and should not be modified without full system recalibration.

Mode and Switch Logic

• Startup H-Pedal
• Brake H-Pedal
• NTL H-Pedal
• Joystick
• Three Gear Switch
• Boost
• Foot Switch
• SW Level
• 0,HIM;1,KIM
• Cruise
• Anti Slip
• Change Dir

These values define how external inputs and controller mode flags interact with operating behavior.

These values are typically binary enable or disable states stored internally as mode flags or bitfields.

Behavior Overview

The controller operates using a dual-loop control structure:

• inner loop regulates motor current (Iq / Id)
• outer loop controls torque demand and speed response

The mapping between exposed gain fields and internal control loops is inferred based on standard FOC architecture and observed behavior.

Diagnostics

Firmware Limitations

The Kelly interface does not expose all internal parameters. These are not exposed through standard Kelly configuration tools.

Common Misconfigurations

Incorrect parameter changes can create issues that appear as hardware faults.

Common patterns:

• Increasing battery current too aggressively

  • causes voltage sag, heat, and reduced battery lifespan

• Increasing phase current without thermal awareness

  • creates strong launch but rapid motor heating

• Excessive regenerative braking

  • increases motor heat
  • can create abrupt or unstable deceleration

• Excessive field weakening

  • increases top speed but causes rapid motor heating and efficiency loss

• Improper throttle dead zone settings

  • results in jerky or unpredictable throttle response

• Mismatched speed limits across modes

  • creates inconsistent riding behavior

• Over-adjusting PID values

  • can cause oscillation, instability, or sluggish response

Real-World Symptoms and Likely Causes

Safe Tuning Workflow

Follow a controlled process when modifying controller parameters:

1. Record all stock values before making changes
2. Change only one parameter at a time
3. Test under real riding conditions after each change
4. Monitor battery sag, motor temperature, and controller response
5. Avoid combining multiple aggressive settings simultaneously
6. Revert immediately if abnormal behavior occurs

Safe tuning depends on:

• understanding parameter relationships
• respecting thermal limits
• observing real-world behavior under load

Final Advice

This configuration should be treated as a stable and verified baseline.

Use it for:

• Controller replacement validation
• Diagnostic comparison against known-good behavior
• Controlled and incremental tuning adjustments

The stock configuration table reflects directly observed controller values and should be considered authoritative for this system.

All additional sections that describe firmware-dependent or non-exposed parameters are provided to explain real controller behavior that is not visible through standard tools.

These extended parameters:

• may exist in firmware without being user-accessible
• may override or reshape behavior from exposed settings
• often explain differences between expected and observed performance

Example values and ranges shown outside the main configuration table are:

• representative of typical Kelly controller behavior
• included to improve understanding of system operation
• not confirmed stock values unless explicitly stated

When tuning:

• prioritize thermal limits and sustained performance over peak output
• validate changes under real load conditions, not just unloaded response
• avoid stacking multiple aggressive changes simultaneously
• revert immediately if behavior becomes unstable, inconsistent, or unpredictable

The most important principle is this:

• visible parameters define intent
• hidden parameters and firmware define actual behavior

Understanding both is required for accurate diagnostics and safe performance tuning.