So a couple days ago I went for a long ride on my board, and everything was fine. But when I went to use it today, the second I tried to take off it would cut out.
I bench tested it and found that even while on the bench under hard breaking and hard acceleration it would cut out. Watching the realtime data on the VESC I saw that I was getting FAULT_CODE_OVER_VOLTAGE when it cut out under breaking, and FAULT_CODE_ABS_OVER_CURRENT when it cut out accelerating.
Fault : FAULT_CODE_ABS_OVER_CURRENT
Current : 64.3
Current filtered : 85.5
Voltage : 25.17
Duty : 0.09
RPM : 642.5
Tacho : 81088
Cycles running : 477
TIM duty : 2432
TIM val samp : 1151
TIM current samp : 14154
TIM top : 26006
Comm step : 6
Temperature : 26.64
Fault : FAULT_CODE_OVER_VOLTAGE
Current : -16.1
Current filtered : -16.3
Voltage : 57.51
Duty : 0.38
RPM : 32104.0
Tacho : 41208
Cycles running : 485
TIM duty : 3745
TIM val samp : 1869
TIM current samp : 6771
TIM top : 9805
Comm step : 6
Temperature : 25.82
I donāt own a VESC but (Well I actually own two but I have yet to use them to create my first board.) but something deep inside tells me that itās odd to see ā80Aā as max motor current, if the VESC can only deliver 60Aā¦
I mean, Iām pretty sure you just have to lower that to 60A. Cause I think atm your VESC lets current through till 80Aās but shutsdown because itās higher than 60A.
Weird, it came set to 80A Absolute max. I changed it to 130A and it seems to have fixed the FAULT_CODE_ABS_OVER_CURRENT problem but the FAULT_CODE_OVER_VOLTAGE issue persists.
Max current ramp step is way too high. If youāve been running it at that (4) you may (Iād say almost guaranteed) develop a DRV error in the future
What is your battery situation? That first error shows a ton of current (60 Amps, when youāve set it for 40) and then youāve got some serious votlage sag. The second error shows the voltage hitting just over 57 volts, which leads me to ask, are you using a BMS? I know some arenāt very happy about regen braking and so they just go over-voltage instead of letting much current back into the pack.
The default current ramp step is 0.04. If youāre at 4 (and didnāt set that yourself, which I canāt see why you would have), then you almost certainly have an old buggy firmware which multiplies that parameter by 10 every time you write changes from BLDC tool. It was quickly fixed (about a year ago) but seems that the firmware is still lingering around. See this thread:
As to your battery situationā¦10s should pretty much never hit the 57 volt limit we usually set, even when braking. What is the exact circumstance where you saw those errors? (ie. riding up a hill, etc).
Is this your āStreet Weaverā build? You mentioned in that thread that youād used 2 modified 6s batteries (because of a single failure in each)ā¦are you still using those batteries? And how did they have issue originally? Iām starting to wonder if some other cells are starting to go as well. A high internal resistance due to aging or defective cells could cause that over-voltage issue.
The errors only started happening after I hadnāt ridden it in a couple days and tried to use it. It would cut out whenever I tried to break and had very little power, and yeah, thatās the build. Initially I figured the batteries were the problem but every cell is around 3.7V. Weird that the VESC still has old firmware, its a brand new one from Torqueboards.
Can I test the internal resistance of the cells using a volt meter?
Interesting. If thatās the case, I may suggest you contact torqueboards about that. He may be liable for DRV errors if your firmware came with the buggy version of 2.18 (they didnāt change the revision number when they fixed the issue, unfortunately, so itās not easy to see which version you have besides trying it)
I think you need something like the iMaxB6 balance charger to get IR. I donāt believe itās as simple as just DC resistance (which is what a standard volt meter would measure)