Kelly Controller Parameters and Behavior for ONYX RCR

Evidence and Firmware Applicability

The recorded stock KLS7230S export is the stock dataset. Additional firmware-dependent, extended, and non-exposed fields in this article contain illustrative ranges and conceptual explanations. They are not verified stock values or a claim that every listed feature exists on every KLS7230S revision. Do not use a representative range as a programming default.

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

See Kelly Controller Stock Settings for ONYX RCR: KLS7230S for the complete reference.

Firmware Reference Scope

The cross-variant field table is in Kelly Controller Firmware Variants and Non-Exposed Parameters. The risk classification below remains with the parameter-behavior discussion.

Parameter Risk Classification

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

Firmware and Non-Exposed Parameter Background

The extended and hidden-field material is illustrative, not verified stock KLS7230S programming data. It is now separated into Kelly Controller Firmware Variants and Non-Exposed Parameters. Use the recorded export and the installed controller’s documentation for actual fields; do not enable a feature because it appears in a cross-variant example.

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.

Related Articles

• Firmware and non-exposed parameter background