This is background on internal controller behavior, not a list of adjustments available in the ONYX Kelly app. The source describes conceptual and firmware-dependent functions that are not established by the documented KLS7230S settings export.
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
| Parameter | Example Value / Range | What It Does |
|---|---|---|
| Torque Command Filter | Low / Medium / High smoothing | Filters how quickly throttle input becomes torque output |
| Current Slew Rate Limit | Example range: 50-300 A/s, implementation-dependent | Limits how fast motor current can increase or decrease |
| Current Loop Saturation Limit | 80-120% of nominal | Caps maximum allowable current demand internally |
| Iq/Id Decoupling Gain | 0.5-2.0 | Improves separation between torque and flux control |
| Speed Loop Output Clamp | 80-120% | Limits how much output the speed loop can request |
| Speed Loop Integral Limit | 50-100% | Prevents excessive accumulation in the speed control loop |
| Flux Observer Gain | 0.1-1.0 | Controls responsiveness of rotor flux estimation |
| Rotor Observer Filter Constant | 10-100 ms | Smooths rotor position estimation over time |
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
| Parameter | Example Value / Range | What It Does |
|---|---|---|
| Deadtime Compensation | 0-100% | Adjusts output to correct errors caused by switching deadtime |
| PWM Deadtime | 500-2000 ns | Inserts a delay between switching events to prevent shoot-through |
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
| Parameter | Example Value / Range | What It Does |
|---|---|---|
| MOSFET Thermal Model | Enabled / Disabled or internal model | Estimates internal transistor temperature beyond sensor readings |
| Thermal Derating Slope | Slow / Medium / Fast | Controls how quickly power is reduced as temperature rises |
| Thermal Foldback Gain | Low / Medium / High | Adjusts how aggressively the controller reduces output under heat |
| Thermal Recovery Rate | Slow (5-10s), Medium (2-5s), Fast (1-2s) | Controls how quickly power returns after cooling |
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
| Parameter | Example Value / Range | What It Does |
|---|---|---|
| Hall Sequence Validation | Enabled / Disabled | Confirms correct hall sensor transition order |
| Phase Alignment Offset | ±0-10° electrical | Applies correction between electrical output and rotor position |
| Auto-Identification State Machine | Auto / Manual trigger | Runs internal motor identification routine |
| Phase Advance Angle (Dynamic) | 0-20° increasing with RPM | Advances timing to improve efficiency at higher speeds |
| Commutation Advance Map | Speed-based curve | Defines how timing advance changes across RPM |
| ID Err | Fault flag (0 = OK, 1 = Error) | Indicates motor identification or rotor position failure |
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
| Parameter | Example Value / Range | What It Does |
|---|---|---|
| Stall Detection Threshold | 10-50 RPM or high current condition | Detects when the motor is not rotating despite torque demand |
| Stall Current Limit | 50-150% of nominal current | Limits current during a stall condition |
| Anti-Stall Recovery Timer | 500-2000 ms | Time before the controller attempts to recover from a stall |
| Slip Detection Threshold | 5-20% speed error | Detects mismatch between expected and actual motor speed |
| Slip Compensation Gain | 0-20% | Adjusts output to correct for slip conditions |
| Overvoltage Regen Suppression | Enabled / Disabled | Reduces or disables regen when voltage approaches limits |
| Regen Disable on Fault Flag | Enabled / Disabled | Turns off regen during fault conditions |
| Fault Latch Behavior | Latched / Auto-clear | Determines whether faults persist until reset |
| Fault Auto-Recovery Enable | Enabled / Disabled | Allows controller to recover automatically after certain faults |
| Watchdog Timer | 100-1000 ms | Resets controller if firmware becomes unresponsive |
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
| Parameter | Example Value / Range | What It Does |
|---|---|---|
| Startup Torque Boost (Internal) | 5-30% | Adds extra torque at initial throttle to help the motor start moving |
| Startup Alignment Current | 10-50A | Applies current to hold the rotor in a known position before startup |
| Startup Alignment Time | 100-500 ms | Duration the controller holds the rotor during alignment |
| Zero Speed Lock Detection | Enabled / Disabled | Detects when the motor is fully stopped |
| Neutral State Current Clamp | 0-10A | Limits current output when the system is in a neutral or idle state |
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
| Parameter | Example Value / Range | What It Does |
|---|---|---|
| DC Bus Ripple Filter | Low / Medium / High | Filters rapid voltage fluctuations from the battery |
| DC Bus Voltage Averaging Window | 10-100 ms | Determines how quickly voltage changes affect controller decisions |
| Dynamic Current Limiting vs Voltage | 0-30% scaling | Reduces output as battery voltage drops under load |
| Power Limiting Curve | Linear / stepped curve | Adjusts available power across the battery voltage range |
| Precharge Detection Threshold | ~60-90% of pack voltage | Determines when it is safe to fully connect the controller |
| Precharge Timeout | 100-1000 ms | Maximum time allowed for precharge before triggering a fault |
| Contactor Delay Control | 50-500 ms | Delays full power engagement during startup |
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
| Parameter | Example Value / Range | What It Does |
|---|---|---|
| Hall Signal Debounce Time | 1-10 ms | Filters noise from hall sensor signals |
| Hall Error Timeout | 50-200 ms | Time before a missing or invalid hall signal is treated as a fault |
| Encoder Signal Loss Timeout | 50-200 ms | Detects loss of encoder signal |
| Resolver Signal Quality Threshold | Example range: 70-95% signal quality, implementation-dependent | Defines minimum acceptable resolver signal integrity |
| Sensorless Transition Threshold | 200-1000 RPM | Speed at which controller may switch between sensor and sensorless operation |
| Sensorless Fallback Enable | Enabled / Disabled | Allows operation if primary sensor signal is lost |
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
| Parameter | Example Value / Range | What It Does |
|---|---|---|
| Throttle Plausibility Check | Enabled / Disabled | Validates that throttle input signals are within expected range |
| Brake-Throttle Override Logic | Enabled / Disabled | Determines whether brake input overrides throttle |
| Direction Change Lockout Timer | 200-1000 ms | Prevents immediate reversal while the motor is still spinning |
| Direction Change Delay Timer | 100-500 ms | Adds delay before applying torque after direction change |
| Reverse Torque Limit | 20-50% | Limits torque when operating in reverse |
| Reverse Speed Clamp | 20-50% of forward speed | Limits maximum reverse speed |
| CAN Timeout Threshold | 100-500 ms | Detects loss of communication over CAN bus |
| Communication Loss Fallback Mode | Coast / Disable / Limp Mode | Defines controller behavior when communication is lost |
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
Evidence and Programming Boundary
The recorded ONYX KLS7230S stock export identifies its own controller/firmware. The representative fields, ranges, conceptual control loops, and hidden features below have not been established by that export. Blank values remain blank. Statements about typical defaults or enabled behavior are source examples, not verified instructions for the reader’s controller.
Kelly publishes manuals for KLS-S and KLS-N families separately. A family-level manual or an example from another revision does not verify every field in this cross-variant list. Use the exact model, firmware, and exposed configuration interface when deciding what is available. Do not infer sensorless fallback, field weakening, PID access, or any other feature from this article alone.
For the observed ONYX parameter relationships and programming workflow, see Kelly Controller Parameters and Behavior . This article preserves the explanatory material without converting it into an authoritative tuning recipe.