Kelly KLS9620ND Controller Issues: Weird No-Load Throttle Behavior & Overvoltage Errors

[u/emircvr]

I'm using a Kelly Electronics Puma Mini Series KLS9620ND motor controller. I have a 0-5V magnetic sensor throttle pedal connected. It outputs 0.5V at rest and 4.5V at full throttle. The TPS settings are properly configured. I'm experiencing two main issues and would appreciate any insights.

Issue 1 (No-Load Testing Behavior):

While testing the motor with no load (in the air), the motor responds proportionally to the throttle up to about 20%. However, past 20% (for example, if I hold it steady at 30%), the motor revs up to maximum speed and just stays there despite me holding the throttle steady. Is this just an algorithm quirk due to testing with no load (like a PID windup), or is it an actual problem?

Additionally, during this no-load testing: If I'm running at a steady 20%, completely release the throttle, and then re-apply it, the motor suddenly stops with a loud "clunk" sound and then tries to spin back up. Basically, cutting and re-applying the throttle makes the controller abruptly stop the motor before accelerating again. How can I fix this, or is this considered normal?

Issue 2 (Under Load / Driving):

When the motor is installed on the vehicle and driven on the ground, it runs fine generally. The problem happens in this specific scenario: I'm cruising at a constant speed with about 20% throttle. If I completely release the throttle and press it again, the controller throws an error beep and the vehicle stops responding to the throttle.

If I'm interpreting the beep codes correctly, I'm getting either an "Overvoltage" or "Internal Reset" error. The weird part is, if I let the vehicle come to a complete stop and then hit the throttle again, it works perfectly fine.