Flipsky 75100 Pro V2.0 failure

[Rocket]

Hi All.

Unfortunately I am not having much luck with my Flipsky products. I borrowed a controller from a friend who had a spare while I am waiting for my replacement VX3 controller to arrive. And now the 75100 Pro V2.0 Vesc that was part of my build has failed.
I used the whole setup 5 times in total (3 times and the controller failed) and then twice more on a friend’s borrowed controller.

I used it for an efoil session with no problems. Then I went to the shower to wash my gear in fresh water and when I tried to get the motor to turn to wash the water out of it, the motor would not turn and made some strange noises and cogged back and forward a tiny bit.

Since then I have been trying to understand what has happened and by using parts that my friend has we have determined that something has failed in the Vesc.

My motor works perfectly with his Flipsky Vesc. And his motor has the same issue when connected to my Flipsky Vesc.

I have completely removed the Vesc from its casing to see if there are any signs of water damage or heating marks but nothing is showing.
The Vesc has definitely had no water ingress.

The Vesc still connects properly to Vesc Tool, the only thing that seems to be not normal is it doesn’t seem to retain the voltage figures in the general tab of the motor settings in Vesc Tool. Other than that it reads the motor and app setting and writes the motor and app settings.

The main thing that fails is when you try and read the resistance and inductance settings. I have included a video of the inductance testing and photos of my motor settings.

If you try and use the setup motor wizard it goes through to the same area of testing and fails there also. Photo of that error included also.

I have only seen a maximum Vesc temp of 53 degrees once. Generally (used 5 times) it has been running below that.

If you watch the video you can see the green and blue lights work but then when it fails to read the resistance and inductance the light goes red.

The UART 3.3V and 5V read the correct voltages. The PPM 5V read correctly also.

I don’t use socket 2 (Hall) or socket 4 (Can+Power)

While sitting powered on both the green light and the blue light are on.

I am worried because I can find no reason for the issue. I would understand if water had gotten in there but no water. No cuts in wires. No strange electrical burning smells. Nothing. I am worried because I don’t want it to be something in my settings that has caused the issue. I have asked friend who are running the same setups and compared their settings and they are very similar they are actually running theirs at 110 amp max and I am only running at 90. they are heavier than me.

Has anyone else had issues with this Vesc that weren’t abuse, overheating or water ingress related?

Please let me know if there is anything else I can try or what can be done to to help me.

Thank you.

[Rocket]

[Jan12]

Reset everything to default.
Try BLDC mode instead of FOC.

Also I could never get any of the “reverse” or “with brake” modes to work with the VX3.
For testing maybe just go “duty cycle no reverse”.

[ludwig_bre]

Share the settings and values found under Motor->FOC on the left, especially the 2nd tab in there with the motor values (resistance, inductance)

Redo whole setup of vesc

When switching controller always redo input wizard

Check if your motor is damaged (measure resistance with external multimeter, or share motor values so we can evaluate)

Which motor are you running?

For setup you can follow this video step by step:

#008-1: VESC Setup for eFoil [Flipsky 65161 & 75200]

[Rocket]

Hi Ludwig

These are the first two tabs of the FOC. I haven’t entered any of these figures they are what the RL and Flux linkage has determined from pressing the button on the first tab. This is the process that now fails but used to work perfectly before the issue.

[ludwig_bre]

Ok
Does it fail at the RL or lambda button?
Try it again, after it fails open the terminal and put “fault” or “faults” there
Any faults recorded?
Also, please check if you have phase filters disabled (foc->filters)

[Kian]

@Rocket
Just for your information.
If you press the print screen button on your laptop [prt sc], you can paste the image directly in the post.
No need to take a picture with your camera!

[Rocket]

Hi Jan12

That still doesn’t explain why it worked perfectly for 5 sessions and during testing and then failed between the water and the shower. Seems a little odd.

I haven’t received any useful info or response from Flipsky yet but hold out hope they will let me know something soon.

[Rocket]

It fails at the RL button and the error message is in this pic which I thought I had posted earlier.

[Rocket]

And Enable phase filters is false.

I understand re print screen. But I’m posting on my phone whilst working on my computer. I’ll do it all on the computer next. I just had all the pics from initial posting

[ludwig_bre]

Hmm
In that case there might actually be a fault or short circuit somewhere.
Any chance you can measure with a multimeter?
Measure: Motor side each phase to each other, resistance
VESC side all phases to each other and each phase both to pos and neg input

Also try running the motor detection with no motor attached - do you also get a overcurren error?

[Rocket]

On the motor side they are all 0.01-0.03 ohms. I don’t think my Multimeter reads finely enough to read the 40 milliohms that it read on my friends Vesc for that motor.

On the Vesc side they were all 116.5

[Rocket]

I am lucky enough to have a friend that has the same Vesc and same motor. After the issue we swapped parts around and this I how we determined that it was the Vesc and not something else. As my motor worked correctly and the Vesc tool could take all the readings and setup my motor with his Vesc. But his motor had the same setup issues and wouldn’t turn when plugged into my Vesc using the Vesc tool setup.

[Jezza]

Have you made sure its not a bad solder joint on the VESC phase connectors?
I have this exact VESC open in front of me and you can’t reliably inspect the power section of the VESC.
If you measure the resistance between your VESC phases unplugged (and no power), you should see about 114kohm.
I’d bet something has shorted or blown in the power circuit.
If you are skilled with a soldering iron its not too hard to get the logic board off the top which will allow you to investigate the power board.

[Rocket]

Hi Jezza.

I am seeing 116.5 across all 3 at the Vesc side

[Rocket]

The other question I had was why would it work using BLDC and not FOC?

Do they use different ways to measure the motor? ie not the resistance and inductance?

[ludwig_bre]

@Rocket

Do they use different ways to measure the motor?

Nope, if you already have a problem measuring motor values, BLDC and FOC will not make any difference.

Did you try to run detection without a motor connected? If so, does that also fail?
If that does not generate an error, can you try to start from scratch on the ESC, ie upload firmware again and do all settings again?

[Jezza]

@Rocket

On the Vesc side they were all 116.5

k-ohm or just ohms? If the latter then its an issue.

[Rocket]

116.5K ohms on the Vesc side

[Monaro]

Just a thought as i had a similar issue. Mine was related to the salty environment in the box where the VESC was installed. Little drops of water from hands etc ended in the box after a few uses and caused corrosion in the PCB and / or connectors. The motor stuttered like there was a phase wire missing. I took the VESC out of the box and apart, washed it with electronic contact spray and it came good again. Since then when I potted all my VESCs in PU compound I never had a problem.