Following up on my earlier question about the TP100 star rewind FOC cutout issue. The root cause turned out to be a wiring mistake — the SS41F Hall sensor pinout (VCC/GND) was reversed throughout testing. Once corrected, VESC Tool confirmed valid Hall tables and the motor now spins freely past the previous cutout threshold.
Current setup:
Motor: TP100, delta350KV → star rewind, targeting ~200KV
ESC: Flipsky 75350, VESC FW 7.0
Battery: 14S LiPo
Background:
The motor ran without issues in its original delta winding (~350KV). Problems appeared only after rewinding to star — initially no Hall sensors, sensorless FOC was cutting out above ~20% duty due to low BEMF in star configuration. Hall sensors (SS41F) were installed to solve the low-speed observer instability.
Progress after pinout fix (log attached):
With Hall sensors correctly wired, the motor reaches ~28,000 ERPM. Through testing we’ve identified two separate issues:
Issue 1 — ABS overcurrent threshold:
FAULT_CODE_ABS_OVER_CURRENT (fault=4) triggers consistently at 101A+ phase current. At 100A limit, clean runs with no ABS fault. The boundary is very sharp — 100A is fine, 101A cuts out. Log shows 141 fault=4 events from earlier runs before the current limit was dialed in.
Issue 2 — Observer instability at Hall/sensorless transition:
Even at 100A limit (no ABS fault), the motor cuts out intermittently at high ERPM. Log shows RPM climbing smoothly to ~27,500 ERPM, then dropping to ~3,700 in a single sample before coasting to a stop — no fault code, just observer losing sync at the Hall/sensorless handoff region.
These are two distinct failure modes — the ABS threshold is a hard current limit issue, the high-ERPM dropout is a sensorless observer issue.
Additional note:
One Hall sensor was found to be angularly misaligned (shifted one slot) during the original installation. Pinout is now correct, alignment is also corrected — attached log predates the alignment fix, so next test will be with both corrections in place.
Questions:
The 100A/101A ABS cutout boundary — is this expected behavior for this motor/ESC combo on 14S, or is there a way to push the threshold higher without triggering overcurrent protection?
For the observer dropout at ~27,500 ERPM — is this a Hall handoff threshold setting or Observer Gain tuning issue on a 12N10P star config?
Could the previously misaligned Hall sensor have left residual errors in the Hall table that affect the sensorless transition even after correction?