Hello,

For the first time since I started flying electrics in 2006 I was not able to log a few flights due to issues with the power system. In essence, the motor would spool up to about 20% of power and then wind down. After the first attempt, the ESC, a Castle HV85, started to beep. My first reaction was that the batteries were not properly charged. Checked voltages, they were O.K., but decided to try a different pack just to be safe. Same thing happened again. On the second attempt, the motor would stutter a little bit before winding down. My first reaction was that maybe the ESC settings had been erased but it also occurred to me that maybe it was a blown capacitor. On the second attempt I did noticed that the spark did not seem very robust.

So, I will be checking the ESC settings as well as the connections to make sure that they are in order. If those check out O.K. would a blown capacitor be a good guess?

Thanks,

Teo

Teo,

When you wrote, "For the first time since I started flying electrics in 2006 I was not able to log a few flights due to issues with the power system.", did you mean the ESC failed to create a data log OR the obvious you didn't fly?

If the ESC created a log of the failures, it would be helpful if you posted the logged data showing the voltage, current, temp etc. in short all its recorded data. You could also compare it against previous successful flights while looking closely for a rise in operating temp, a decrease in rpm which could indicate a bearing going bad etc.


J e r

Jer,

I meant, I missed the opportunity to fly. In essence, this is the first time I have been grounded by a power system issue since converting over to electrics. The ESC can log data, but other than making the initial measurements when setting it up, I have not kept track of the data. I will take a look at the settings today to see if some how they got erased and re-set. I somehow doubt it.

Thanks,

Teo

What were the beeps you were getting. They are actually error codes..

I believe that it was the low voltage cutoff. It was single beep, spaced about 1 second apart.

Teo,

The logged data will show the battery voltage and ripple. If its low voltage it'll stick out like a sore thumb. The ripple will show if the input capacitors are bad.

Were both incidents using the same battery pack?


J e r

I will see if I can download the data, I do have a Castle Link somewhere. I may have to take the plane apart to get at the ESC. After the first incident, I swapped packs. I re-checked voltages and both packs were good, 20.7-20.8 volt per 5 cell pack (x2 for a flight pack).

Teo,

You get the data by unplugging the throttle lead from the ESC to the receiver and plugging the link into the ESC end, no need to take the plane apart, just unplug the cable. You may need to have the battery attached to the ESC on some Castle ESC's.

J e r

If you never changed any of the settings it shouled be set to defaulted factory settings

Hi -

I have not been able to check on the ESC. Things at work have been a little crazy. I should be able to hook it up the Castle Link over the holidays and get an idea of what is going on. Either way, I believe that there is an issue with the ESC so it will have to come out either to be serviced or replaced.

Thank you for the advice,

Teo

I have a CC 85 that checks good on the castle link, but will not arm, not sure why

I believe you also have to make sure it will match your motor. IE how many poles are the windings of your motor. Also calibrate it to your radio. Make sure you do not have any switch turned on to basically shut off throttle.

Check the model of the ESC. The HV 85 is an older Phoenix model that does not have logging. It is still a very robust ESC that is totally programmable through the Castle Link Software. Best firmware for that model it 3.20.

Hi -

I had a chance to work on the airplane and as it turns out, the controller is an ICE HV 80. Paying attention to the the beeps, I noticed that I was getting 3 beeps followed by a pause. I looked it up and it is an indication of an over current condition. While doing the run up, I had hooked up a watt meter which only read about 5 amps before the motor stuttered and stopped. I tried the ESC on a different motor and got the same result.

I was able to hook up the controller to the Castle link and download the data which I have enclosed. Looking at it, the controller seems to think that I was hitting 120 amps in the 800 or so seconds which were recorded. The initial portion of the recording might correspond to the last flight before the controller went bad. The plane is propped for a max current of about 70 amps so seeing the 120 amp in the log seemed surprising. I believe that the data is not correct as I do not remember the last good flight as being unusual. At the end, the batteries took back about 3000 mah which was normal consumption based on my previous experience (Advanced sequence plus a few extra maneuvers at the end; total flight time of about 7:30 minutes).

The motor I use is a Pletty Evo 25-12. The prop is a 20x13 carbon fiber. So now I am wondering a few things:

1) I suspect that a capacitor has failed due to the weak spark when I arm the system.
2) I wonder if the motor and prop combination is to blame... The 20x13 is at the limit of what plettenberg recommends for the motor; probably too big on 10S.
3) Are the motor and controller a good match, or would I be better off with a different controller.

Either way, I will be sending the controller in for repairs, I believe that it needs them. Any insight or suggestions would be appreciated.

Thank you,

Teo

If you have the ICE HV 80, I believe these were subject to recall in 2011. The advisory says to not fly them. Your problems sound like it should be replaced.

http://www.castlecreations.com/service-advisory-2011-03

Thank for the tip. I did not know that. I checked the controller and it is labeled as ICE 2; so it is one of the newer ones (bought in '12). I will send it in and see what they have to say.

I've used E-Flite motors and Castle ESC's since converting to E-power about 5 years ago, with one 'over current' shut down on a 75A esc after running about 60 seconds at half throttle (low current draw). Castle replaced or fixed it. I have yet to have a problem with an HV-85.