I have unfortunately had three Flipsky 75100 Pro V2.0 fail. I have potted each Vesc and have had no water ingress whatsoever either into the box holding the Vesc or the Vesc itself.
I can’t remember the exact issue with the first failure as it was in June. But the latest two I have a reasonable amount of info. The second one ran faultlessly for about a month then started cutting out giving cogging style of issues I spent many weeks trying to replicate the issue consistently but it was intermittent and very hard to analyse. After checking all my RTData on Vesctool there were no significant amp readings or temp readings. Max amps around 110 with 20-30 being normal from remote when cruising around. Temps maxed out at 52 on one session but normally maxed out at 47. Eventually the Vesc stopped turning the motor altogether and so it had to go. Now that I have had my third failure I decided to pull that second Vesc apart to see if there were any telltale signs of deterioration and the only thing that showed up was when I started pulling on the cable to check the solders and their connectedness the first one pulled off the board very easily. See picture. Is this what other are mentioning as checking for bad solders or is this something else? I can’t see how this could be fixed other than a big improvement in the building of the Vesc and that attachment at creation by Flipsky.
The third failure was quite different. Everything was working perfectly for about 6 weeks. Then out of nowhere the system just started cutting out about 30 minutes into a session. I would sit around for a minute or two and then it would work again for about 10 minutes and then cut out again. There was no consistency or what I was doing when this happened. I could be cruising around, it would cut out. I could be coming off a wave and pull the trigger and nothing would work. I could cruise in and dropped into the water to talk to a mate and then not be able to get the prop to spin with even the slightest trigger pull. Again no high temps 52 max, amps max of 111.
Eventually and I was extremely lucky that this happened onshore with the battery cover off the Vesc basically caught fire whilst attached to the battery. Luckily I was able to disconnect the battery and get it away from the Vesc and I have a feeling if it the Vesc want potted I could have been in a little bit more trouble than that. Pretty sure an 11S3P fire would have been a bit sketchy.
I pulled the Vesc apart and this is the result. See pics.
I have followed Ludwig’s setup video and feel that I am not stressing the Vesc with my temp and amps so is there anything else I can try in the Vesc tool to try and prevent these issues or is the Vesc really just not up to the task?
Any help would be appreciated.
Motor and battery setup below.
