Homemade Electric Buggy, Ep 10: Wiring & Programming Kelly Controller - ME1616 Motor

[@JamesBiggar]

I sound like an idiot 🙄 Would have been hard to explain all this without narrating it though. Let me know if you prefer this format or want me to go back to giving you the silent treatment lol

[@unom8]

Eh, you are doing great - your voice is fine :) that motor sounds beautiful though!

[@MiniLuv-1984]

No problem for me. I listen like an idiot. :) All info is good info. I was thinking to put the pre-charge resistor across the contactor too, but hadn't seen it before, so figured I was overlooking something. I realised after watching you that I've been thinking about this for the wrong part of the circuit - before the controller but also before other feeds...wrong! Muchas gracias!

[@JohnathonBrock]

Nah the voice over was appreciated. Can't wait to see it on the trails!

[@steveseeger]

You made the right call, thanks for taking the extra time to do a voice over.

[@Area_Man]

Most of your videos are easily understood without narration but I think it was needed here. Great work!

[@PrayingLotus]

I’m gonna be completely honest, I have no clue what’s going on, but it sounds rather detailed and impressive and thorough, so I dig it

[@brettfullmer8914]

Dude, you are a genius. I mean that, too. Not many people can do EVERYTHING that you do so well. Lots of knowledge, wisdom and understanding of all these trades. Bravo!

[@JamesBiggar]

Thanks man. But no genius here - I just learned from others. Carpenter by trade. I didn't start playing with ev's until a few years ago.

[@rogereheadbyrne4790]

James Thank You For all you do!! This Project is Awesome!!This Crosscart is something else!!

[@SimonasB]

This is insane amount of work! wow

[@JamesBiggar]

Yep.

[@theecstatic9686]

Worth it...

[@JakeItsTheCops]

I thoroughly enjoy the level of detail you including your videos. Can’t wait to see it running full tilt but have definitely enjoyed the journey!

[@kimbrohmutete6327]

Nm

[@kimbrohmutete6327]

Zmt.

[@kimbrohmutete6327]

M

[@kimbrohmutete6327]

Mmp

[@DktheWelder]

Probably the most awesome cross kart ever! I can’t believe how technical it is to build electric stuff

[@belgrademachine]

Very good to hear your voice and I'm impressed with the variety of your skills as usual James. I would continue with this format; you are super clear and organized. One of the best channels on YT!!

[@JamesBiggar]

Thanks Darryl!

[@midwestbest6398]

sounds great can't wait to see this thing take off

[@sheanyquist]

Thanks for the detailed video!!! I needed this when j was doing my build!!!!

[@greatdane3343]

Awesome build mate! I hope it performs as you deserve.

[@JamesBiggar]

Thanks! I love it, it works great! Drive video will be published Sunday morning.

[@WaveMaster1406]

I really love this project that I'm particularly following with some interest.

[@proaudiorestore8926]

Well done James! It’s looking great

[@Jammed_Toast]

Narration gives some great insight! Your work is so clean and tidy. Cant wait to see it running. Edit: That motor sounds gnarly!

[@zmanpianoman]

Great job James. Takes a lot of work to get that little gear to spin.

[@JamesBiggar]

Thanks!

[@chris_1337]

Fantastic work as always James! The electrical tape on the tools was a smart idea!

[@JamesBiggar]

Thanks 👍

[@OverbuiltByHenry]

That's a complete nightmare of wires and I love it! The sound of that motor spinning certifies that it will vaporize tires. Just saying but the battery is going to last longer than the tires. You are going to make me build myself one, thanks for the vid!

[@j.p289]

You are amazingly skilled mate

[@utkutan]

That looks gorgeous. Great work man 👍

[@douglasharley2440]

utterly amazing!...as always, *respect.* lol, i find it a lil alarming that it's gonna be able to go just as fast backwards as forwards. 😳

[@rickreid8149]

Thanks James

[@juan.2438]

Imagine this beauty with solid state sulfur sodium batteries

[@PhG1961]

Awesome and very impressive !

[@Bigrob552002]

You da man!!!! I am so glad you gave a little extra filming time so we could see that motor drive gear spin. This whole projects has incorporated so many different areas of technical skill and knowledge. After this project is said and done. Do you think you might hold an AMA?

[@maxv1455]

Да, ждем твоего следующего видео!

[@AllThingsElectric_]

Hey man, how were you able to wire the reverse switch? I have the same controller in a hall sensor version but do not know what the FWD and REV pin on the controller requires to activate them.

[@blackterminal]

Can you use more than one of those BMS in one set of batteries?

[@joserolandsancheromero4440]

Que gran proyecto, esta muy bueno, excelente y da angustia esperar tanto para ver el proceso de el mismo pero a la vez es emocionante❤️🎊👏

[@barajasprototype2714]

How many batteries did you install? And how many cells were used? Very good vehicle, and today you have inspired me to build my own buggy

[@seisette]

It appears it's already pretty noisy like this, maybe if you can find a transmission with straight-cut gears you could ditch the siren. It gets pretty "whiny" though. As always, phenomenal work!

[@JamesBiggar]

The current diff and the chain both add enough noise with the motor and tires that I really don't see the need for the siren either. It's plenty loud enough imo.

[@Nun3zDanny3]

What did you do to weatherproof stuff? Like if you need to wash it after a dirty session, how would you do that?

[@JamesBiggar]

Garden hose. Sponge. Whatever. The modules are sealed. Both the battery and myself get soaked any time I hit a puddle (water flies off the front wheels with no fenders to stop it). Motor is liquid cooled so obviously it's waterproof. Everything else, excluding transmission cables, is protected undercover the same as sensitive electrical components in any other vehicle.

[@JamesBiggar]

...by 'undercover' I mean that I made body panels to cover everything that needs to be protected from either water or debris.

[@unom8]

Different applications for sure, but both roboteq and keya controller software seems much more advanced, interested in hearing your perspective if you have the chance to try them out for something smaller in the future

[@3dconceptsofutah757]

Thank you for showing your setup! I have a Kelly and Motenergy setup too but it seems to stall and makes loud noises art different stages through the RPM range. Fanny is trying to help resolve it without any luck yet. Have you seen that before with your Kelly setups previously? Thanks!

[@JamesBiggar]

I did have issues with power cutting out under hard acceleration. Zero point, amplitude and angle identification all worked properly. I determined that the current the ME1616 was pulling on the AC (output) side of the controller was around 10 amps higher at full throttle than what the controller could handle, though DC input was fine. On the 'vehicle' page of the user program, I changed the current % (for the motor - not to be confused with the motor current setting on the motor page - that's only for angle identification), as well as the battery current to 95 instead of the default 100. The controller now limits the input and output current to 95% of its rating without tripping the overcurrent protection. I also set the forward MAP to 50. Fany suggested trying 80 because I wanted full power immediately, the moment that I put the pedal to the floor, but that seemed to cause overcurrent issues again with the surge of power. The MAP setting determines whether the throttle input is exponential, linear or logarithmic, ie how much current is delivered depending on the position of the throttle; 30 = exponential, 50 = linear, 80 = logarithmic. These are just a benchmark, you can choose any number between them. It took a couple of weeks to get it tuned in the way I want but it's now working pretty good. Has no problem kicking up dirt and scaring the heck out of me lol. I'm heading out in a few minutes for day 2 of shooting the final drive footage. If I were to use another Motenergy motor, I would probably invest in a Sevcon controller. They're quite a bit more expensive but they're what I consider a 'performance' controller, better suited for race machines. A guy I'm following built his own race car with 2 of the ME1616's and two Sevcon controllers, and they deliver full power the moment he stomps the throttle for a drag race. There's always a bit of a lag with the Kelly controllers it seems. But they work fine for the price. All controllers take a bit of work to get them tuned in.

[@Coatchawa]

Hey James! I have found sources that say the output shaft on the ME1616 is 7/8", and I have also found that the output shaft referred to as 1-1/8". Can you confirm which it is?

[@JamesBiggar]

Sure, it's a 7/8" dia shaft, approx 1-3/8" long. You can download a schematic and model here: www.electricmotorsport.com/ev-parts/motors/brushless-pmac-ipm-motors/me1616-brushless-65hp-liquid-cooled-ipm-motor-24-120v.html

[@blackterminal]

what did you mean by 85 angle instead of 170?

[@antiLeixo]

what do you use to charge the motor?

[@mohammadgulrahim1800]

Hi sir big fan You are a great person ☺️ Keep it up 😉

[@JamesBiggar]

Thanks! I have my flaws too though

[@actionkey8042]

awesome

[@entheogen22]

Ты крут 💯

[@kolbeck69]

awesome --

[@rkaid7]

He speaks, sounds Canuck. I sorta figure u were eastern bloc. Fan of years, keep it up, extremely entertaining from Australia.

[@JamesBiggar]

Thanks! East coast born and raised.

[@oa1583]

What size wire did u use to run from the battery to the controller???

[@JamesBiggar]

1/0 awg (53.5mm²)

[@oa1583]

Any updates on this project.. is the kelly controller still working heard about alot of internal blow out... can we have a 1 year or 2 year update

[@JamesBiggar]

kzbin.info/www/bejne/o53KmoKgeMqeiqs

[@milfordadkins1662]

hey, ive got exact same motor and controller. can you send me a screen shot of the controller setting and sine cosighn settings?

[@LSVideo-t6z]

Hello, can you help me. I send a signal from terminal number 11 to terminal 14 or 12, nothing changes, the engine spins in one direction. locks in the program are all off. Through the computer I can only change the direction of the engine

[@hayden9944]

Ur a cross between Tony Stark, Mad Max and a Canadian.

[@JamesBiggar]

LOL!

[@ksriram1997]

🖤

[@wagnerbrochini3892]

Hi James! Congratulations on all your work, such a compendium of useful information for us DIYers trying to make electric vehicles. On a side note, I'm planning a very similar build to this but in a motorcycle, do you know what is the maximum torque available on your setup? I'm having a hard time figuring out the ideal reduction ratio to meet both acceleration and maximum speed desired performance, any help is greatly appreciated! BTW, subscribed to you now, keep the builds coming!!

[@JamesBiggar]

Thanks! Max torque for the ME1616 is 120 nm, or 89 ft-lb, which can be sustained with peak amps for

[@ruftxinde]

鎖 電池 需 用 銅螺絲 銅墊片

[@Mexicanhanu]

Is there a reason you choose Kelly controller over the sabvoton?

[@JamesBiggar]

Because I know it.

[@Mexicanhanu]

@@JamesBiggar i am looking for a controller and was wondering if you had a main reason for using kelly. Seeing most of ur videos i can see you prefer kelly, but is there a defining part that would benefit from using kelly over sabvoton?

[@JamesBiggar]

I've never used Sabvoton beyond using a pre-programmed kit in a previous build, so I really can't say what they're like to program, but I find no difference in terms of driving. I know how to tune the KLS controllers to just about any motor, so I stick with these unless someone can give me good reason to learn a new program.

[@JamesBiggar]

Update: took it out for a drive today, my recommendation is to NOT get a Kelly IPS controller like mine (sine/cosine type). The controller won't deliver peak power in low speed/high torque scenarios (

[@Mexicanhanu]

@@JamesBiggar Damn That is unfortunate. is that just a traction control setting or is that the IPS controllers attempt to make sure that the motor does not go out of phase?

[@renecorrea8769]

Hello again, how are you? You asked me if you would sell me only the plans of the cage, since your design and construction are very good, please, I need to do a project.

[@RileyPorter]

What contactor are you using?

[@JamesBiggar]

ZJW600A, 12V version (coil is powered by the isolated 12V circuit): kellycontroller.com/shop/zjw-600a-main-contactor/

[@derschutze7715]

James my friend Your are wunderfull. How any Batterys You install on your Buggy. 76. Like Very beautifull work and Buggy. Sincerely James.

[@JamesBiggar]

32 modules in series

[@derschutze7715]

@@JamesBiggar and how much ampere when I may ask you.

[@JamesBiggar]

Check out the battery build video linked in the description, all the specs are there bud

[@derschutze7715]

@@JamesBiggar Thank You very much James. I wish You nice Day. I am Abo I follow Your wonderfull works. Thank You very much for sharing James. Nice Day .

[@JamesBiggar]

Cheers!

[@cristianhernandezsanchez7486]

Hola una pregunta me gustaría hacer un carro igual al tuyo será mucho pedir los planos del chasis del carro

[@majintks]

What top speed do you think it will have?

[@JamesBiggar]

120 km/h, twice the speed it needs as a trail buggy. I can't see anyone ever driving that fast on a trail unless they're a really talented adrenaline junky. It's not a highway passenger vehicle, so top speed is irrelevant. Fast acceleration (ie torque) is more important in this context, and more fun.

[@majintks]

@@JamesBiggar OMG! i need to see that haha

[@majintks]

Of course, you don't need to go that fast to have fun. Intrigued by the next video friend ⚡😀🚀

[@mdasif-fu4do]

Hi jams

[@EnergySeeker]

what are these battery ? what ratings ?

[@JamesBiggar]

The specs are great, and their cost is the most affordable you'll find unless you buy used: batteryhookup.com/products/100-brand-new-lifep04-32650-3-2v-6000mah-cells

[@EnergySeeker]

@@JamesBiggar so you made it in this format yourself ? do you have a video of how you did that ?

[@JamesBiggar]

Yes, check out the links in the video description.

[@EnergySeeker]

@@JamesBiggar thanks will do

[@EnergySeeker]

@@JamesBiggar why dont you sell that as a product ? i mean the battery module , ready to be used

[@TECHSUPPORTEBIKE]

HOLLY SHIT OMG BEAST

[@blackterminal]

Controller link is dead. Please can you list the model number.

[@felikswielkopolan4001]

quick reverse i have to say ahhah

[@alexsamonin8132]

As a sapper - one awkward movement and there is no battery.

[@deanmav3571]

You damage the rotor and bearings

[@JamesBiggar]

You damaged your brain.

[@MiniLuv-1984]

I wonder how much more work it would take to make that street legal? Here is Australia it would require incredible commitment, cash and dealing with monkeys.

[@JamesBiggar]

In most of North America it would just be a matter of adding things like fenders, mirrors, wipers, lights, etc. Basic safety equipment. It doesn't have a solid axle like other crosskarts so it's safe to operate on asphalt without having to peel the tires and drift around corners to compensate for understeering (this is one of the reasons why a typical atv can't be licensed for use on public roads). I don't plan on licensing for the road, but I did install the LSD just in case.

[@nastyakondratieva3592]

Блок предохранителей нехвотает

[@JamesBiggar]

Неправильный. Все четко сплавлено в линию. Пожалуйста, смотрите схему подключения, прежде чем комментировать конфигурацию подключения.

[@drtiagofernandez]

Sell it to me !!!

[@mjc2ride336]

As impressive as it is, siting next to that much electrical spaghetti would scare the living crap out of me! I'll choose gasoline, thanks anyway.

[@JamesBiggar]

It shouldn't - your gas tank is more likely to kill you, statistically speaking. But to each their own, I'm not here to tell you what to drive, just show you what I did. Check out the other videos in the build series, most of the videos don't focus specifically on the electric powertrain - you could put anything you want in this buggy :)

[@shito3892]

Said it back then say it now your ma hero!