This guide outlines essential safety checks to perform regularly on your VESC setup, emphasising the importance of promptly addressing potential safety concerns.
DISCLAIMER: The VESC Bible is currently being republished and rewritten to encompass all necessary beginner guides. All guides with a beta tag are still preliminary and need to be vetted and reviewed by VESC experts.
Battery Checks
- Voltage: Regularly check the overall battery voltage, especially before and after rides. This helps you monitor the battery’s state of charge and identify potential issues early on. When opening the board, use a voltmeter and check the voltage at the main battery connector (usually an XT60 connector).
- Balance: Monitor the individual cell voltages within your battery pack. An unbalanced pack can lead to reduced performance and, in extreme cases, pose a safety risk. This is particularly important when the battery is at nominal voltage (around half charge), near empty, and at full charge. Many BMS (Battery Management Systems) offer the ability to view individual cell voltages. If your BMS does not offer this feature, you can use a voltmeter to check individual cell groups through the balance connector.
- Temperature: Pay attention to the battery temperature, especially during and after charging or heavy use. Excessive heat can indicate a problem with the battery or charging system. Avoid charging or using a hot battery until it has cooled down. While there is no specific information in the sources about a specific temperature range, it is important to note that excessive heat is not good for a lithium-ion battery and can lead to a decrease in its lifespan.
Connection Integrity
- Motor: Inspect all motor connections for tightness and signs of damage. Loose or faulty connections can cause erratic motor behaviour or even complete failure.
- Battery: Ensure the main battery connector is firmly seated and shows no signs of melting or damage. Regularly inspect the battery wires for secure connections.
- VESC: Check all connections to the VESC, including power, motor, sensor, and communication cables. Ensure the connectors are properly seated and the wires are undamaged.
- Other Components: Inspect the connections of any additional components, such as lights, displays, or external sensors, ensuring they are secure and free from damage.
Component Temperature
- VESC: Overheating can indicate excessive current draw, inadequate cooling, or a potential fault within the VESC Controller. Ensure proper airflow around the heatsink and consider adding a fan for active cooling, especially during demanding riding conditions.
- Motor: Touch the motor housing to assess its temperature. Overheating can signal an overloaded motor, insufficient cooling, or internal issues. Ensure the motor has adequate ventilation and consider adding a fan if necessary.
- Charger: Make sure to use a reliable high quality charger to prevent issues in the first place. Monitor the charger’s temperature during operation. Excessive heat can suggest a malfunctioning charger, potentially posing a safety hazard. Discontinue use immediately if the charger becomes abnormally hot.
Importance of Promptly Addressing Safety Concerns
Any unusual observations during your safety checks should be investigated and resolved immediately. Ignoring potential issues can lead to serious consequences, including component failure, battery damage, and even personal injury.
If you encounter a problem you cannot resolve yourself, seek assistance from qualified technicians or the community. Provide detailed information about the issue, including any relevant observations, error messages, and troubleshooting steps you’ve already taken. This will enable others to offer targeted advice and help you find a solution safely and effectively.