Yesterday, I started getting DRV8302 errors on my TB VESC 4.12 after riding the board without issues for more than 600km. This would happen most of the time as soon as I pulled the throttle on startup, but sometimes it worked fine without giving any errors. As soon as the board started rolling, I could pull the throttle without any errors at all and it would work perfectly.
When I got home, I connected the VESC to the VESC tool to see if anything was wrong with the settings. After that, it stopped working completely and the VESC would only make a high pitched noise whenever I pulled the throttle (https://www.youtube.com/watch?v=kya4sDUbt1U).
I then decided to swap around the master and slave VESC (dual setup), and it seems that the VESC causing the issues was the master VESC (now the slave VESC). The other VESC works fine. After swapping them around, both of the motors are spinning again. However, upon startup the bad VESC seems to lag behind a little bit (good VESC starts spinning immediately upon pulling the throttle, other one takes a second or two and then immediately spins at full power). There have been no more DRV errors after swapping around the VESCs.
There are no visible signs of damage on the DRV chip or anywhere else on the bad VESC. When the board is moving, both VESCs work perfectly. The only time issues arrive is during startup. Sometimes it feels like the bad VESC completely cuts out during startup, and then starts working again once the other VESC has the board moving.
My board has the following specs: Trampa 35º holypro deck 15ply, ratchet bindings, vertigo trucks, superstar wheels 8S 25Ah 20C lipo, 740Wh (10x 4S 5000mAh zippy flightmax) dual TB VESC 4.12 (running in FOC mode) dual turnigy aerodrive SK3 6364 245Kv motors metr pro bluetooth module
Gearing ratio 13:72. The top speed of the board is around 45km/h. I usually ride close to the top speed, and this gives me a range of around 35km (I charge the lipos to 4.15V and stop discharging at around 10% to increase their cycle life).
Is there anything else that could be wrong with the VESC besides the DRV chip? I know running in FOC mode increases the risk of the DRV chip frying, but it seems weird that the VESC still works normally when the board is