FAULT_CODE_ABS_OVER_CURRENT fault happens mostly when going over any bump

ESK8 Electronics
1

I built a newish esk8 and it seems to stall for a few seconds if I go over even the smallest bump and sometimes at random. On some rides its fine and only stops once or twice but other times it will stop every few seconds making it impossible to ride. I have about 20km on it so far.

I have tried setting the motor max and batt max lower and increasing the absolute max but it doesn’t make a difference. The voltage during the faults seems to be incorrect because my battery was at about 40v but the fault reported it as ~31v

Specs: 10s4p Samsung 25R battery pack 190kv torque boards motor FOCBOX 82mm wheels 16t/36t

FOCBOX settings

Capture
Capture1401×828 41.7 KB
Capture1
Capture11400×827 31.5 KB

Here is the faults:

The following faults were registered since start:

Fault : FAULT_CODE_ABS_OVER_CURRENT Current : 156.0 Current filtered : 134.6 Voltage : 31.95 Duty : 0.61 RPM : 66.1 Tacho : 11582 Cycles running : 5976 TIM duty : 4010 TIM val samp : 1898 TIM current samp : 5165 TIM top : 6534 Comm step : 6 Temperature : 25.11

Fault : FAULT_CODE_ABS_OVER_CURRENT Current : 156.0 Current filtered : 136.2 Voltage : 32.49 Duty : 0.49 RPM : 1018.6 Tacho : 14980 Cycles running : 12639 TIM duty : 3890 TIM val samp : 1797 TIM current samp : 5805 TIM top : 8017 Comm step : 2 Temperature : 25.37

Fault : FAULT_CODE_ABS_OVER_CURRENT Current : 156.0 Current filtered : 130.5 Voltage : 31.87 Duty : 0.61 RPM : 301.2 Tacho : 17822 Cycles running : 8706 TIM duty : 4011 TIM val samp : 1899 TIM current samp : 5162 TIM top : 6527 Comm step : 6 Temperature : 25.57

Fault : FAULT_CODE_ABS_OVER_CURRENT Current : 156.0 Current filtered : 135.3 Voltage : 31.25 Duty : 0.58 RPM : 109.5 Tacho : 21202 Cycles running : 7000 TIM duty : 3979 TIM val samp : 1872 TIM current samp : 5328 TIM top : 6912 Comm step : 2 Temperature : 25.70

Fault : FAULT_CODE_ABS_OVER_CURRENT Current : 156.0 Current filtered : 134.6 Voltage : 32.69 Duty : 0.46 RPM : 14.8 Tacho : 34218 Cycles running : 4464 TIM duty : 3862 TIM val samp : 1773 TIM current samp : 5952 TIM top : 8358 Comm step : 4 Temperature : 26.26

Fault : FAULT_CODE_ABS_OVER_CURRENT Current : 156.0 Current filtered : 137.3 Voltage : 31.93 Duty : 0.56 RPM : 10.8 Tacho : 43024 Cycles running : 5463 TIM duty : 3963 TIM val samp : 1858 TIM current samp : 5417 TIM top : 7118 Comm step : 2 Temperature : 26.95

Fault : FAULT_CODE_ABS_OVER_CURRENT Current : 156.0 Current filtered : 137.7 Voltage : 30.48 Duty : 0.58 RPM : 120.1 Tacho : 51802 Cycles running : 83770 TIM duty : 3987 TIM val samp : 1879 TIM current samp : 5288 TIM top : 6818 Comm step : 2 Temperature : 28.13

Fault : FAULT_CODE_ABS_OVER_CURRENT Current : 34.9 Current filtered : 130.0 Voltage : 35.66 Duty : 0.75 RPM : 72.5 Tacho : 56634 Cycles running : 5598 TIM duty : 4094 TIM val samp : 2044 TIM current samp : 4790 TIM top : 5492 Comm step : 4 Temperature : 28.63

Fault : FAULT_CODE_ABS_OVER_CURRENT Current : 156.0 Current filtered : 133.4 Voltage : 32.10 Duty : 0.53 RPM : 512.7 Tacho : 63772 Cycles running : 28521 TIM duty : 3942 TIM val samp : 1841 TIM current samp : 5530 TIM top : 7378 Comm step : 2 Temperature : 28.86

Fault : FAULT_CODE_ABS_OVER_CURRENT Current : 156.0 Current filtered : 138.0 Voltage : 30.59 Duty : 0.59 RPM : 529.1 Tacho : 69922 Cycles running : 2652 TIM duty : 3991 TIM val samp : 1882 TIM current samp : 5268 TIM top : 6773 Comm step : 2 Temperature : 29.07

Fault : FAULT_CODE_ABS_OVER_CURRENT Current : 156.0 Current filtered : 134.6 Voltage : 32.36 Duty : 0.46 RPM : 5.0 Tacho : 83308 Cycles running : 30138 TIM duty : 3860 TIM val samp : 1771 TIM current samp : 5964 TIM top : 8386 Comm step : 2 Temperature : 28.91

Fault : FAULT_CODE_ABS_OVER_CURRENT Current : 156.0 Current filtered : 131.2 Voltage : 32.70 Duty : 0.50 RPM : 0.1 Tacho : 87450 Cycles running : 16334 TIM duty : 3910 TIM val samp : 1813 TIM current samp : 5700 TIM top : 7773 Comm step : 4 Temperature : 28.84

Fault : FAULT_CODE_ABS_OVER_CURRENT Current : 156.0 Current filtered : 132.3 Voltage : 32.21 Duty : 0.57 RPM : 1034.2 Tacho : 90224 Cycles running : 6665 TIM duty : 3978 TIM val samp : 1871 TIM current samp : 5337 TIM top : 6932 Comm step : 2 Temperature : 28.78

Fault : FAULT_CODE_ABS_OVER_CURRENT Current : 136.6 Current filtered : 130.6 Voltage : 39.89 Duty : 0.20 RPM : -0.0 Tacho : 94361 Cycles running : 0 TIM duty : 840 TIM val samp : 1995 TIM current samp : 4095 TIM top : 4200 Comm step : -1 Temperature : 28.86

Fault : FAULT_CODE_ABS_OVER_CURRENT Current : 0.4 Current filtered : 133.6 Voltage : 40.20 Duty : -0.00 RPM : 1117.7 Tacho : 122334 Cycles running : 26070 TIM duty : -263 TIM val samp : 131 TIM current samp : 26505 TIM top : 52747 Comm step : 6 Temperature : 30.04

Fault : FAULT_CODE_ABS_OVER_CURRENT Current : 132.9 Current filtered : 130.2 Voltage : 39.89 Duty : 0.19 RPM : 1.6 Tacho : 125973 Cycles running : 0 TIM duty : 780 TIM val samp : 1995 TIM current samp : 4095 TIM top : 4200 Comm step : -1 Temperature : 30.33

Fault : FAULT_CODE_ABS_OVER_CURRENT Current : 156.0 Current filtered : 132.1 Voltage : 32.10 Duty : 0.60 RPM : 60.4 Tacho : 125980 Cycles running : 1052 TIM duty : 4001 TIM val samp : 1891 TIM current samp : 5211 TIM top : 6640 Comm step : 6 Temperature : 30.39

Fault : FAULT_CODE_ABS_OVER_CURRENT Current : 156.0 Current filtered : 130.7 Voltage : 32.36 Duty : 0.49 RPM : 288.1 Tacho : 130440 Cycles running : 5537 TIM duty : 3895 TIM val samp : 1801 TIM current samp : 5777 TIM top : 7953 Comm step : 2 Temperature : 31.32

Fault : FAULT_CODE_ABS_OVER_CURRENT Current : 156.0 Current filtered : 131.2 Voltage : 32.25 Duty : 0.56 RPM : 87.1 Tacho : 313108 Cycles running : 2956 TIM duty : 3968 TIM val samp : 1863 TIM current samp : 5390 TIM top : 7054 Comm step : 6 Temperature : 37.25

Fault : FAULT_CODE_ABS_OVER_CURRENT Current : 156.0 Current filtered : 130.7 Voltage : 31.96 Duty : 0.56 RPM : 73.4 Tacho : 323712 Cycles running : 41463 TIM duty : 3968 TIM val samp : 1863 TIM current samp : 5387 TIM top : 7048 Comm step : 6 Temperature : 36.39

Fault : FAULT_CODE_ABS_OVER_CURRENT Current : 119.1 Current filtered : 131.0 Voltage : 39.96 Duty : -0.00 RPM : 2689.1 Tacho : 335749 Cycles running : 67253 TIM duty : -263 TIM val samp : 131 TIM current samp : 26505 TIM top : 52747 Comm step : -1 Temperature : 37.34

Fault : FAULT_CODE_ABS_OVER_CURRENT Current : 156.0 Current filtered : 131.6 Voltage : 39.80 Duty : 0.00 RPM : 768.8 Tacho : 351287 Cycles running : 0 TIM duty : 0 TIM val samp : 247 TIM current samp : 2347 TIM top : 4200 Comm step : -1 Temperature : 37.80

Fault : FAULT_CODE_ABS_OVER_CURRENT Current : 139.7 Current filtered : 130.2 Voltage : 39.62 Duty : 0.00 RPM : 483.7 Tacho : 365831 Cycles running : 0 TIM duty : 0 TIM val samp : 183 TIM current samp : 2283 TIM top : 4200 Comm step : -1 Temperature : 38.09

Does anyone have any troubleshooting ideas or can see anything wrong with my setup. I have looked through a bunch of threads here but I cant seem to find anything that relates to this. EDIT: It happens at any speed including slower than a walking speed.

2

Doing a small search on this forum reveals to me you might have something funky going on with your vesc. Do a quick search you’ll likely find the answer.

3

My guess would be a loose connection somewhere creating a short amp spike. Check if your bullet connectors have a tight connection etcetera…

1 Like
4

I have made sure the bullet connectors, sensor connector and the input power cables are all connected well.

5

I have tried searching it but nothing seems to relate to my exact problem.

6

This happens when components are not soldered on correctly. Check your caps and shunts. Sometimes problems only come to light under close scrutiny, like two bridged legs or small solder balls etc.

EDIT: This could also be caused by long battery wires(ripple current). For every additional 30cm of battery wire going to the vesc, caps should be added.

7

Thanks for the response! I am not sure how to check the components on the FOCBOX as it is all screwed together. I might try opening it up and look and my battery wires are 10 gauge and about 50cm for the wiring between the cells and about 40cm straight from the negative and positive terminal to the FOCBOX. How big of capacitors should i consider adding?

8

63v 1000 uF

9

will a 50v 2200uF capacitor work cause my batteries are at 42v and they are the only ones i have on hand.

10

That’ll work fine.

11

I was going to say that maybe the capacitor legs had broken from vibration.

1 Like
12

I had this problem before, when i test my settings, all are good/working but when i enclosed it in the board, it didnt work, and have same faults, i did was, i re-routed my wires, made it short and secure ( make sure wires doesn’t move) and all is working!

13

with the added capacitor I am still getting the same faults. I also opened the FOCBOX and both the capacitors were attached and all of the rest of the components looked fine. Any other ideas?

The following faults were registered since start:

Fault            : FAULT_CODE_ABS_OVER_CURRENT
Current          : 82.4
Current filtered : 137.3
Voltage          : 36.64
Duty             : 0.30
RPM              : 1212.6
Tacho            : 73264
Cycles running   : 11092
TIM duty         : 3567
TIM val samp     : 1685
TIM current samp : 7687
TIM top          : 12004
Comm step        : 4
Temperature      : 31.29

Fault            : FAULT_CODE_ABS_OVER_CURRENT
Current          : 101.5
Current filtered : 133.6
Voltage          : 36.34
Duty             : 0.23
RPM              : 882.5
Tacho            : 76105
Cycles running   : 763
TIM duty         : 3340
TIM val samp     : 1477
TIM current samp : 8877
TIM top          : 14800
Comm step        : 1
Temperature      : 31.21

Fault            : FAULT_CODE_ABS_OVER_CURRENT
Current          : 120.2
Current filtered : 132.5
Voltage          : 38.79
Duty             : 0.00
RPM              : 378.6
Tacho            : 115613
Cycles running   : 750
TIM duty         : 263
TIM val samp     : 131
TIM current samp : 26505
TIM top          : 52747
Comm step        : 5
Temperature      : 33.02

Fault            : FAULT_CODE_ABS_OVER_CURRENT
Current          : 156.0
Current filtered : 131.3
Voltage          : 33.50
Duty             : 0.60
RPM              : 656.9
Tacho            : 116550
Cycles running   : 13024
TIM duty         : 4003
TIM val samp     : 1892
TIM current samp : 5204
TIM top          : 6624
Comm step        : 2
Temperature      : 32.10

Fault            : FAULT_CODE_ABS_OVER_CURRENT
Current          : 156.0
Current filtered : 131.8
Voltage          : 34.27
Duty             : 0.33
RPM              : 591.1
Tacho            : 118649
Cycles running   : 2274
TIM duty         : 3648
TIM val samp     : 1590
TIM current samp : 7092
TIM top          : 11004
Comm step        : 5
Temperature      : 32.07

Fault            : FAULT_CODE_ABS_OVER_CURRENT
Current          : 156.0
Current filtered : 132.8
Voltage          : 33.67
Duty             : 0.46
RPM              : 556.9
Tacho            : 119376
Cycles running   : 5037
TIM duty         : 3861
TIM val samp     : 1771
TIM current samp : 5960
TIM top          : 8378
Comm step        : 2
Temperature      : 31.93
14

Open your Focbox one if the caps legs is broken

15

I checked and the capacitor legs are still attached

16

Can you upload your vesc settings?

17

I posted the motor and BLDC settings in the original post. Do you want screenshots of other setting pages? I have updated the FOCBOX firmware from 2.18 to 3.37 or 3.38 and switched the motor to foc mode and it seems to work now but i did not get to do any extensive testing yet.

18

If it still doesnt work properly attach some pictures of the vesc PCB. That way we can See if it looks faulty or not

19

I was getting shutdowns at some point when I passed over tram rails. My solution was slowing down at 15 km/h.

20

sounds like something is loose somewhere, could be a whole lot of things - might even be the motor shorting under impacts. Check all connections and components, if nothing helps, try a new vesc