Over Voltage protection for full charge battery

Hi,

I have a question regarding protection from over voltage. I’m using in my build only balancer (not BMS) like this one: LINK

How can I protect my battery from over voltage when my battery is fully charge (I know, that is not good for battery;)) and I need to start braking on the beginning my ride ?

VESC - Flipsky Dual FSESC6.6 Plus based on VESC6
Battery - 12s7p 21700 LGM50T
Motors - Trampa 136kV Hall Sensor

Most people just throttle around for a bit before braking.

Others stop their chargers a bit short of “full” so they have the extra headroom for braking.

Few use a device called a rheostatic brake that takes the extra regenerated voltage and is wired in parallel with the battery.

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Roll down backwards, so u throttle forward to “brake” :joy:

or

Accelerate downwards, then brake :crazy_face:

The correct way to do this is with a braking resistor and heatsink. I know Maytech sold a 10S one, I haven’t seen any others available commercially, but you could make one.

Use a smart bms, charge only and set it to 4.15V per cell cut off.

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But I don’t want use BMS :slight_smile:

One time I overcharged a board by over 7 volts on accident doing this. It’s a really good thing it was a LiFePO4 board.

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Just use a voltmeter so you can stop charging at whatever voltage you want

Use a charger with adjustable voltage so you can set it to ~4.1-4.15v/cell.

Or put a couple diodes in series to drop the voltage reaching the pack by ~0.6-1.2 volts.

So there is no option to set this over voltage protection somehow inside VESC settings ?

My goodness, what kind of hill were you going down? A whole mountain?

I always thought the regen function was really inefficient. No? I watched one video of a guy trying to charge his dead board by riding downhill, and he was getting terrible results, but it was a low power street board.

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the problem lies in where the energy goes once the battery pack regen past its max voltage

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Lifepo4 would jump voltage so fast after the capacity is full…

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There is an overvoltage protection feature in the vesc settings - It disables the brakes to keep from reaching the overvoltage.

If you want to always have brakes, you have to stay below the vesc’s overvoltage limit.
That means either A) setting the vesc limit significantly above 4.2v/cell so it won’t shut off the brakes (risky and really bad for the cells), or B) setting it to 4.2-4.25v/cell and don’t charge the battery all the way.
You have to have room either way - Either you’re starting at 100% and going over, or you’re starting at like 90-95% and going towards 100.

Exactly this one I’m looking for. Where I can set it ?

Yeah what @Fosterqc said

It was LiFePO4, which is also the reason I probably didn’t have a fire at +7.3V over charge on 12S

But once they get full the voltage goes up fast. Standing there while the ESC idled for 10 minutes brought it back down to +1.0V over and the rest I burned off by running the motors, first with the wheel in the air, then riding it up the hill.

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How does the VESC disconnect/ignore the brakes? I always assumed you needed something like a big resistor, or a bank of them, to burn off the power the motors make? How does this work?

It simply stops braking

That sucks.