This is a separately labeled background reference for the blog’s Kelly firmware-dependent and non-exposed parameter discussion. It is not a stock ONYX settings article or confirmation that these fields exist on a specific controller.
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.
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.
| Field | Value | Notes |
|---|---|---|
| Min Excitation | Lower bound of field weakening behavior | |
| Max Excitation | Upper excitation limit before weakening transitions | |
| Field Weakening Enable | Typically enabled in performance configurations | |
| Flux Weakening % | Controls strength of high-speed field reduction | |
| Max Regen Current | Primary limiter of regen strength | |
| Regen Current Limit | Caps regen regardless of brake % | |
| EBS Level | Firmware-dependent regen scaling | |
| Torque Limit | Internal torque ceiling | |
| Max Torque Command | Limits requested torque before output stage | |
| Absolute Speed Limit | Hard RPM ceiling independent of throttle | |
| Bus Voltage Compensation | Increases current to offset voltage sag | |
| Power Limit vs Voltage | Reduces output as voltage drops | |
| Torque Mode / Speed Mode | Typically torque mode for vehicle applications | |
| Regen Enable Modes | Determines when regen is allowed to engage | |
| Direction Change Protection | Typically enabled to prevent unsafe reversal under load | |
| Brk_Speed Limit | 100 RPM | Minimum RPM where regen becomes effective |
| Low Speed Regen Cutoff | Further reduces regen near zero speed | |
| Regen Ramp Rate | Controls how quickly regen torque builds | |
| Regen Voltage Clamp | Limits regen near overvoltage threshold | |
| Regen Current Slew Limit | Smooths regen current transitions | |
| High Temp Str C | Start of thermal derating (below 170°C cutoff) | |
| High Temp Weak % | Strength of thermal derating | |
| Thermal Derating Slope | Rate of power reduction with temperature | |
| Thermal Foldback Gain | Aggressiveness of thermal limiting | |
| Thermal Recovery Rate | Speed of power restoration after cooling | |
| Max Torque Clamp | Hard internal torque ceiling | |
| Torque Limit vs Speed Curve | Reduces torque as RPM increases | |
| Torque Derate vs RPM | High-speed torque reduction behavior | |
| Electrical Frequency Clamp | Limits max electrical output frequency | |
| Back EMF Compensation | Adjusts output at high speed | |
| Field Weakening Ramp Rate | Speed of weakening engagement | |
| Hall Sequence Validation | Prevents invalid hall transitions (typically enabled) | |
| Phase Alignment Offset | Fine adjustment of commutation timing | |
| Auto-Identification State Machine | Runs during motor identification (startup or triggered) | |
| Phase Advance Angle (Dynamic) | Increases with RPM for efficiency | |
| Commutation Advance Map | Speed-based timing adjustment | |
| Dynamic Current Limiting vs Voltage | Reduces output during voltage sag | |
| DC Bus Ripple Filter | Smooths voltage fluctuations | |
| DC Bus Voltage Averaging Window | Response speed to voltage changes | |
| Precharge Detection Threshold | Typically ~60-90% of pack voltage | |
| Precharge Timeout | Prevents failed startup condition | |
| Contactor Delay Control | Controls engagement timing | |
| Reverse Torque Limit | Typically reduced vs forward torque | |
| Reverse Speed Clamp | Limits reverse speed | |
| Direction Change Lockout Timer | Prevents immediate reversal | |
| Direction Change Delay Timer | Adds delay before torque reapply | |
| Torque Command Filter | Smooths throttle-to-torque response | |
| Current Slew Rate Limit | Limits current rise/fall speed | |
| Current Loop Saturation Limit | Caps internal current demand | |
| Iq/Id Decoupling Gain | Improves FOC control separation | |
| Speed Loop Output Clamp | Limits speed loop authority | |
| Speed Loop Integral Limit | Prevents integral wind-up | |
| Flux Observer Gain | Rotor estimation responsiveness | |
| Rotor Observer Filter Constant | Smooths rotor position estimation | |
| Deadtime Compensation | Corrects switching delay losses | |
| PWM Deadtime | Prevents transistor shoot-through | |
| MOSFET Thermal Model | Internal temperature estimation (typically enabled in firmware) | |
| Stall Detection Threshold | Detects non-rotating motor under load | |
| Stall Current Limit | Limits current during stall | |
| Anti-Stall Recovery Timer | Delay before retry | |
| Slip Detection Threshold | Detects mismatch in expected speed | |
| Slip Compensation Gain | Adjusts torque during slip | |
| Overvoltage Regen Suppression | Typically enabled to protect battery from overvoltage | |
| Regen Disable on Fault Flag | Commonly enabled to disable regen during fault conditions | |
| Fault Latch Behavior | Latched | Requires reset after fault |
| Fault Auto-Recovery Enable | Allows automatic recovery | |
| Watchdog Timer | Firmware safety reset timer | |
| Startup Torque Boost (Internal) | Improves launch from stop | |
| Startup Alignment Current | Holds rotor before movement | |
| Startup Alignment Time | Duration of alignment phase | |
| Zero Speed Lock Detection | Typically enabled to detect stopped motor state | |
| Neutral State Current Clamp | Prevents unintended movement | |
| Hall Signal Debounce Time | Filters noisy hall signals | |
| Hall Error Timeout | Detects signal loss | |
| Encoder Signal Loss Timeout | Detects encoder failure | |
| Resolver Signal Quality Threshold | Minimum valid signal level | |
| Sensorless Transition Threshold | RPM where fallback may occur | |
| Sensorless Fallback Enable | Allows operation without sensors (firmware-dependent) | |
| Throttle Plausibility Check | Typically enabled to prevent invalid throttle input | |
| Brake-Throttle Override Logic | Commonly enabled so brake input overrides throttle | |
| CAN Timeout Threshold | Detects communication loss | |
| Communication Loss Fallback Mode | Defines behavior when communication is lost (disable / limp / coast) | |
| ID Err | Diagnostic flag for identification failure |
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
| Parameter | Example Value / Range | What It Does |
|---|---|---|
| Min Excitation | 5-15% | Sets the lower excitation floor used when weakening begins |
| Max Excitation | 80-100% | Sets the upper excitation limit available before weakening behavior changes |
| Field Weakening Enable | On / Off | Enables or disables field weakening behavior |
| Flux Weakening % | 5-20% mild, 20-40% aggressive | Controls how strongly the controller reduces effective field strength at high RPM |
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
| Parameter | Example Value / Range | What It Does |
|---|---|---|
| Max Regen Current | 10-30A mild, 30-60A strong | Sets the upper limit for how much regen current the controller can send back into the battery |
| Regen Current Limit | 10-50A | Caps regen output regardless of brake percentage settings |
| EBS Level | 1-3 light, 4-6 medium, 7-10 aggressive | Sets the overall strength of electronic braking behavior, depending on firmware scale |
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
| Parameter | Example Value / Range | What It Does |
|---|---|---|
| Torque Limit | Example range: 60-100% typical, 100%+ less restricted | Caps maximum motor torque output |
| Max Torque Command | Example range: 50-100% | Limits how much torque the controller will request internally |
| Absolute Speed Limit | Example range: 12000-18000 RPM | Sets a hard ceiling on motor speed regardless of throttle input |
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
| Parameter | Example Value / Range | What It Does |
|---|---|---|
| Bus Voltage Compensation | 0-10% mild, 10-25% aggressive | Adjusts output to compensate for voltage sag under load |
| Power Limit vs Voltage | Linear or stepped curve | Reduces available power as battery voltage drops |
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
| Parameter | Example Value / Range | What It Does |
|---|---|---|
| Torque Mode / Speed Mode | Torque (default), Speed (less common) | Determines whether throttle controls torque output or targets a speed |
| Regen Enable Modes | Off / Throttle Release / Brake Only / Combined | Defines when regenerative braking is allowed to engage |
| Direction Change Protection | Enabled / Disabled | Prevents unsafe direction changes while the motor is still rotating |
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)
| Parameter | Example Value / Range | What It Does |
|---|---|---|
| Brk_Speed Limit | 100 RPM | Minimum motor speed at which regenerative braking becomes active |
| Low Speed Regen Cutoff | Example range: 0-100 RPM below active regen region | Further tapers or disables regen as speed approaches zero |
| Regen Ramp Rate | Slow / Medium / Fast | Controls how quickly regen torque is applied |
| Regen Voltage Clamp | Near pack overvoltage threshold | Limits regen current as battery voltage approaches protection limit |
| Regen Current Slew Limit | Low / Medium / High or firmware-dependent ramp rate | Limits how quickly regen current can rise or fall |
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)
| Parameter | Example Value / Range | What It Does |
|---|---|---|
| High Temp Str C | Typical example range: 120-150°C | Temperature where the controller starts reducing output |
| High Temp Weak % | Low / Medium / High or firmware-dependent scaling | Controls how aggressively power is reduced once thermal limiting starts |
| Thermal Derating Slope | Shallow / Medium / Steep | Controls how quickly output falls as temperature rises |
| Thermal Foldback Gain | Low / Medium / High | Shapes how strongly the controller folds power back under heat |
| Thermal Recovery Rate | Slow / Medium / Fast | Controls how smoothly power returns after cooling |
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)
| Parameter | Example Value / Range | What It Does |
|---|---|---|
| Max Torque Clamp | Example range: 80-120% | Sets an internal hard ceiling on torque output regardless of other limits |
| Torque Limit vs Speed Curve | Linear / stepped reduction | Reduces available torque as speed increases |
| Torque Derate vs RPM | Starts ~60-80% of max RPM | Gradually lowers torque at higher motor speeds |
| Electrical Frequency Clamp | Example range: 800-1200 Hz, firmware-dependent | Caps maximum electrical output frequency |
| Back EMF Compensation | 0-20% | Adjusts output to account for increasing back EMF at high speed |
| Field Weakening Ramp Rate | Slow / Medium / Fast | Controls how quickly field weakening is applied as speed increases |
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
| Parameter | Example Value / Range | What It Does |
|---|---|---|
| Hall Sequence Validation | Enabled / Disabled | Verifies correct hall sensor transition order |
| Phase Alignment Offset | ±0-10° electrical | Applies correction to align controller output with motor position |
| Auto-Identification State Machine | Run on startup / manual trigger | Handles automated motor identification and calibration |
| Phase Advance Angle (Dynamic) | 0-20° increasing with RPM | Advances timing as speed increases for efficiency |
| Commutation Advance Map | Speed-based curve | Defines how phase advance changes across RPM range |
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)
| Parameter | Example Value / Range | What It Does |
|---|---|---|
| Dynamic Current Limiting vs Voltage | 0-30% scaling | Reduces output as battery voltage drops under load |
| Power Limiting Curve | Linear / stepped curve | Defines how available power changes across voltage range |
| DC Bus Ripple Filter | Low / Medium / High filtering | Smooths rapid voltage fluctuations from the battery |
| DC Bus Voltage Averaging Window | 10-100 ms | Determines how quickly voltage changes affect control decisions |
| Precharge Detection Threshold | ~60-90% of pack voltage | Detects when safe precharge voltage is reached before enabling full power |
| Precharge Timeout | 100-1000 ms | Sets how long the controller waits for precharge before faulting |
| Contactor Delay Control | 50-500 ms | Delays full engagement to protect components during startup |
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)
| Parameter | Example Value / Range | What It Does |
|---|---|---|
| Reverse Torque Limit | 20-50% typical | Limits available torque when operating in reverse |
| Reverse Speed Clamp | 20-50% of forward speed | Caps maximum reverse speed |
| Direction Change Lockout Timer | 200-1000 ms | Prevents immediate direction changes while motor is still spinning |
| Direction Change Delay Timer | 100-500 ms | Adds a delay before applying torque after a direction change |
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
| 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