Makerbase VESC 84100HP Controller User Manual

1. Introduction

The Makerbase VESC 84100HP is a high-performance motor controller designed for electric mountain bikes, skateboards, and similar applications requiring robust power management. This controller features a wide operating voltage range, high continuous and pulse current capabilities, and advanced control options through the VESC TOOL software.

It incorporates a three-phase splitter and adjustable current/voltage filter. Current sampling utilizes phase line sampling with the ultra-precision dual-channel current detection amplifier INA241A, ensuring high accuracy (gain error ±0.01%, offset voltage 10μV) and wider common mode voltage for reliable motor data detection.

The MKSESC 84100HP also includes a built-in Bluetooth module for convenient configuration and monitoring via mobile devices.

Figure 1: Makerbase VESC 84100HP Controller

2. Specifications

2.1 Key Features

• Phase line current sampling method for precise control.
• Wide operating voltage: DC 14V-84V (4S-20S).
• Continuous Current: 100A; Maximum Pulse Current: 200A (dependent on external heat dissipation).
• Maximum speed limit: 150000ERPM, enhancing motor speed.
• Built-in USB interface for PC configuration, monitoring, and control via VESC TOOL.
• Integrated Bluetooth module for wireless configuration and monitoring via mobile devices.
• Built-in current and phase filters.
• Supports one-key power on/off and timed shutdown.
• Compatible with both sensorless and sensored motors.
• Supports various motor types: BLDC brushless, Hall, DC, GPD.
• Multiple control modes: duty cycle, speed, and current control.
• Communication interfaces: PPM (RC servo), Analog (ADC), UART, I2C, USB, and CAN bus.
• Comprehensive protections: overcurrent, high/low voltage, temperature, and adjustable speed limit.

Figure 2: Detailed Product Features

2.2 Technical Parameters

Table 1: Makerbase VESC 84100HP Technical Specifications

2.3 Internal Components

• CPU: STM32F405RGT6 with 168MHz main frequency and DSP function.
• MOSFETs: 6 HYG015N10NS1TA large current MOSFETs (100V/380A).
• Heat Dissipation: Aluminum substrate material and aluminum alloy casing for effective heat diffusion and protection against foreign matter.
• Bluetooth Module: Integrated for wireless communication.

Figure 3: CPU and Phase Line Current Sampling

Figure 4: MOSFET Configuration

Figure 5: Heat Dissipation Mechanism

Figure 6: Integrated Bluetooth Module

3. Setup and Wiring

Careful wiring is crucial for the safe and proper operation of your VESC 84100HP controller. Always ensure power is disconnected before making any connections.

3.1 Overview of Ports

Figure 7: VESC 84100HP Port Layout

The controller features various ports for battery, motor, communication, and sensors:

• Battery: Main power input (+ and -).
• Motor: Three phase outputs (A, B, C) for motor connection.
• Antenna: For Bluetooth communication.
• USB: Type-C port for PC connection and VESC TOOL.
• PPM: For RC servo/PWM signal input (e.g., remote control receiver).
• CAN: CANL, CANH for CAN bus communication with other VESC devices.
• SWD: SWDIO, SWCLK, GND, 3.3V for debugging/programming.
• COMM: Multi-purpose port for various peripherals (PowerSW, ADC2, TX/SCL, RX/SDA, ADC1, GND, 3.3V, 5V).
• AUX/SENSE: For sensor connections (VCC, TEMP, HALL1, HALL2, HALL3, GND, 5V, HALL, AS5047, ABI).

3.2 Wiring Diagram

Figure 8: VESC 84100HP Main Wiring Diagram

1. Battery Connection: Connect your battery's positive (+) and negative (-) terminals to the corresponding large terminals on the VESC. Ensure correct polarity to prevent damage.
2. Motor Connection: Connect the three phase wires (A, B, C) from your motor to the corresponding motor output terminals on the VESC. The order of A, B, C may affect motor direction and can be adjusted in software.
3. Antenna: Connect the Bluetooth antenna to the designated ANTENNA port.
4. USB: For initial setup and firmware updates, connect a Type-C USB cable from the VESC to your PC.
5. PPM/PWM: If using an RC receiver or similar device for control, connect its signal output to the PPM port.
6. CAN Bus: For multi-VESC setups, connect CANL and CANH between controllers.
7. Sensors (Hall/ABI/AS5047/AS5048A): If your motor has sensors, connect them to the AUX or SENSE ports as per your motor's wiring.

3.3 COMM Port for Throttle/Brake

Figure 9: COMM Port Throttle and Brake Wiring

The COMM port can be used for connecting analog throttles and brakes:

• Throttle Wiring (COMM 1): Connect your throttle's signal, ground, and power wires to the appropriate pins on the COMM port (e.g., ADC1/ADC2 for signal, GND for ground, 3.3V/5V for power).
• Brake Wiring (COMM 2): Similarly, connect your brake's wires to the COMM port.

Important Note: The ADC pins on the COMM port only accept 3.3V signals. Ensure that any connected throttle or brake provides a 3.3V power supply, not 5V, to the ADC port to prevent damage.

3.4 DC-DC Switch and VCC Switch

• VCC Switch: This switch allows you to select the voltage supplied to sensors (VCC). Refer to your sensor's specifications to choose the correct voltage.
• DC-DC Switch:
  • **KEEP ENABLE:** In this mode, the controller remains powered on, and its power state is not controlled by the "SHUTDOWN" pin.
  • **SHUTDOWN:** This mode enables the "SHUTDOWN" function. The motor can be started and turned off via the "PowerSwitch" pin on the COMM port.

4. Operating the Controller

The VESC 84100HP controller is configured and operated using the VESC TOOL software, available for both PC and mobile devices.

4.1 VESC TOOL Software

VESC TOOL allows you to:

• Configure motor parameters (e.g., motor type, current limits, voltage limits).
• Calibrate input devices (e.g., throttle, remote control).
• Monitor real-time data (e.g., mileage, speed, current, battery voltage, temperature).
• Update firmware.
• Diagnose issues and read error codes.

For detailed instructions on using VESC TOOL, please refer to the official VESC TOOL documentation and tutorials.

Figure 10: VESC TOOL PC Interface for Configuration and Monitoring

Figure 11: VESC TOOL Mobile Interface for On-the-Go Monitoring

4.2 Firmware Compatibility

Ensure that the VESC TOOL version you are using is compatible with the controller's firmware version:

Table 2: Firmware and VESC TOOL Compatibility

5. Maintenance

To ensure the longevity and optimal performance of your VESC 84100HP controller, follow these maintenance guidelines:

• Keep Clean: Regularly clean the controller to prevent dust and debris buildup, especially around the heat sink fins. Use a soft brush or compressed air.
• Check Connections: Periodically inspect all wiring connections for looseness, corrosion, or damage. Secure any loose connections.
• Ensure Proper Heat Dissipation: The aluminum casing is designed for effective heat dissipation. Ensure that the controller is mounted in a location with adequate airflow and is not obstructed. Avoid operating in excessively hot environments without additional cooling if pushing high currents.
• Inspect for Physical Damage: Check the casing and connectors for any signs of physical damage.

6. Troubleshooting

If you encounter issues with your VESC 84100HP controller, consider the following troubleshooting steps:

• No Power:
  • Check battery connections and ensure the battery is charged.
  • Verify the DC-DC switch setting. If in SHUTDOWN mode, ensure the PowerSwitch pin is correctly activated.
• Motor Not Spinning/Irregular Operation:
  • Double-check motor phase wire connections (A, B, C).
  • Verify sensor connections if using a sensored motor.
  • Ensure motor type settings in VESC TOOL match your motor (FOC, BLDC, DC).
  • Check for error codes in VESC TOOL. Common errors include DRV8302 faults (often due to incorrect motor settings or short circuits).
• Overcurrent/Overvoltage/Undervoltage Protection Triggered:
  • Review your current and voltage limits in VESC TOOL.
  • Ensure your battery voltage is within the controller's operating range (14V-84V).
  • Reduce load on the motor or check for mechanical obstructions.
• Overheating:
  • Ensure adequate airflow around the controller.
  • Reduce continuous current draw or consider additional cooling solutions if operating in demanding conditions.
  • Check motor and battery for excessive heat as well.
• Communication Issues (USB/Bluetooth):
  • For USB, ensure the correct drivers are installed and the cable is functional.
  • For Bluetooth, ensure the antenna is connected, Bluetooth is enabled on your device, and the VESC TOOL app has necessary permissions.
  • Verify firmware and VESC TOOL version compatibility (refer to Table 2).

For more advanced diagnostics and specific error code interpretations, consult the VESC TOOL software and the broader VESC community resources.

7. User Tips

• Initial Setup: Always perform a motor detection and input wizard in VESC TOOL during initial setup to ensure optimal and safe operation.
• Conservative Settings: When first configuring, start with conservative current and power limits in VESC TOOL. Gradually increase them as you become familiar with the system's behavior.
• Temperature Monitoring: Pay attention to the controller's temperature, especially during the first few rides or under heavy load. Use VESC TOOL's real-time monitoring feature.
• Secure Mounting: Mount the controller securely to prevent vibrations and physical damage. Ensure it's protected from water and excessive dust.
• Regular Checks: Periodically check all electrical connections for tightness and signs of wear. Loose connections can lead to intermittent issues or damage.

8. Warranty and Support

For warranty information, technical support, or service inquiries, please contact your retailer or the manufacturer directly. Keep your proof of purchase for any warranty claims.

Ensure you have the product model (VESC 84100HP) and any relevant serial numbers ready when contacting support.