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Maytech 75/300 R2 v.6.02 fault

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Ai
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Maytech 75/300 R2 v.6.02 fault

Hello!

Got the maytech 75/300 controller with 5.03 firmware, but of course vesctool said that it is old and therefore connection is somehow limited.

I've uprgaded to 6.02 and that's where all the fun began.

It is working, kind of... but the ABS_Overcurrent fault is always popping up when I'm try to accelerate a bit harder than 80-100 phase amps.

The motor is ko RS motor on surron light bee x.

The battery is stock 38Ah 60V 16S samsung q cells, 6C rating

Motor current settings are ~250A

Absolute max is ~350A

Battery current is 200A

 

And this is what I see from the fault print page in terminal:

 

Fault            : FAULT_CODE_BOOTING_FROM_WATCHDOG_RESET
Motor            : 1
Current          : 0.0
Current filtered : 0.0
Voltage          : 63.20
Duty             : -0.004
RPM              : -0.0
Tacho            : 723
Cycles running   : 0
TIM duty         : -20
TIM val samp     : 2800
TIM current samp : 2800
TIM top          : 5600
Comm step        : 0
Temperature      : 31.83
 
Fault            : FAULT_CODE_ABS_OVER_CURRENT
Motor            : 1
Current          : -12201.9
Current filtered : -1128.8
Voltage          : 61.34
Duty             : 0.950
RPM              : 4862.7
Tacho            : 84
Cycles running   : 50854
TIM duty         : 5319
TIM val samp     : 2800
TIM current samp : 2800
TIM top          : 5600
Comm step        : 0
Temperature      : 31.15

 

 

The current readings are off the charts for some reason.

This was all ok in 5.03 version. May be I need to rollback to 5.03?

Ai
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Well, update on my problem. Rolled back to 5.03 and then again upgraded to 6.02 somehow solved almost everything. Runs smooth and nice, but only on 300A current on the motor. Anything above triggers ABS_OVERCURRENT even on no_hw_limits frimware.. and sometimes the controller resets by watchdog before showing the fault..

Are there any way to bypass 300A limit?

TheFox
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Hi
I have also the problem with the FAULT_CODE_ABS_OVER_CURRENT

Did you solve the problem?

Best regards Frank

 

 

edilger
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Hi,

it sounds exactly as the faults I get, as described in 'Watchdog reset not locatable'. In my understanding, the overcurrent is just a result as the software already lost control. The watchdog should never get triggered, and also in my case, I sometimes get no error message at all, when reset happens. Be careful with the error messages, in this case they might be quite old. I always check the printed VOLTAGE of the watchdog reset. If this did not change, it is an old message (the readings of consecutive measurements are most unlikely the same). Unfortunately in this case the SW looses control, so frying the VESC is getting likely. So don't mix up the watchdog reset with the over current.  FAULT_CODE_ABS_OVER_CURRENT might happen also due to a parameter setting which is not perfect, but   FAULT_CODE_BOOTING_FROM_WATCHDOG_RESET should never happen, especialy when it shows 0 current and 0 ERPM , which means that the VESC ist idling. Of course, motor was running when the SW lost control, DRV-chip stopped the motor ( with FAULT_CODE_ABS_OVER_CURRENT) , and the watchdog reset a few ms later does not see any current. In my measurements I also could see truncated FAULT_CODE_ABS_OVER_CURRENT (i.e. at DUTY or RPM- line) without any further message, as the SW reseted on its own before the watchdog was triggered. At least, I am now able to reproduce the fault quite constantly. So if anyone has an idea how to narrow the fault by measurements, let me know, I tried almost every combination by now with only little result.

Ai
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Tomorrow I will test my setup with upgraded fets and caps to 100V, the stock was 80V. And shunts were replaced from 0.5 to 0.2 mR.

Too bad maytech didn't provide any info on any question. Just silence...

 

Stay tuned)

edilger
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It would be quite helpful to narrow the reason for the Watchdog reset, just changing components to get somehow a working setup does not eliminate the root cause, which would help others. The SW should be able to handle all kinds of 'strange measurements'. I fiddled around with software versions as well, sometimes the fault disappeared for a while this way, but sometimes doing the same procedure, no change. It feels as if there is a hidden parameter that gets set after a while ( like a parameter that gets learned) , and not getting reset with parameter-resets, but sometimes does get reset....    I still think ( or guess) that the processing of the Back-EMF is generating the SW-crash. Please keep us updated...good luck

Ai
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Hi! Just a little update.

I've doubled the shunts on each phase and nothing happened. Still 300A and dog coming... Really tired of this.

Finally I gave up on this controller and switched to flipsky 75/500... that is at least have nice support team and really open source.

Now this maytech is for sale... may be someone buy it and eventually get rid of watchdog somehow...

Ai
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Ok guys! Maytech is sold)

I'm pretty happy with 75500 flipsky, already got 900A from it and everything looks good! Bike runs like crazy!