Stephan,
I finally have a Curtis 1238 drive system set up on the bench so I can confirm some settings etc. over the next few days.
Disclaimer: Depending on your software or level of access to the controller, there may be parameters described that you don't find.
I forgot to start the curtis programming station logging.
From the logging table a couple posts back I see a gap of around 8 seconds between two of the lines, is this normal logging output? I have not used your version of the software or logging on this device and usually just watch the live outputs. Logging cant hurt, but if there are big time gaps between data points you may miss crucial parts of the event as they can happen quickly.
I can't recall what happened first. Either I turned off the car or at around 3000 rpm, or it turned off by itself for unknown reason.
Take a pic or write down your fault history. Then clear fault history
Now follow this process when diagnosing issues with your controller:
1-Keyswitch on, check for no fault blinks or active faults after startup and main contactor closing.
2-Do whatever test you are doing, monitoring, whatever. Take your time, observe. You are still on your driveway.
3-If you experience anything that seemingly registers a fault and/or opens the main contactor, don't turn off keyswitch. Record active faults and fault history, then clear fault history. Turn off keyswitch.
4-Goto 1 for next test.
Only change one variable (rewiring, reconnecting, moving harnesses around, cleaning/lubing, changing parameter) if possible for each test.
Obviously if you are worried about motor runaway damage to drivetrain you can turn off the key in an emergency.
What is the fastest the motor RPMs have gone during a runaway test? What is the fastest they can go on a good test? Do either of these correspond with the programmed max motor RPM settings? (possibly found in several places under varying names depending on your controller software). Do any of those test speeds correspond with ANY settings in the program tree that contain the letters "LOS" (limited operating strategy)?
I start to doubt if this was a throttle problem.
Maybe not, but you have been getting throttle faults. Could be that multiple small problems exist further complicating our efforts. Cars that have long naps don't wake up easy, trust me.
Have you removed the BMS relay from throttle line(s)? Have all connectors related to the throttle and encoder circuit been inspected/cleaned/inspected?
If you find the value --Program - Throttle - HPD/SRO Type - - if it is not set to 2, do so. Ensure the parameter change is sent and sticks. Main contactor may open. Cycle key. Write down every change you make and switch them back after your next set of tests.
Looking back at the screen I am keen to learn about the difference between Controller current RMS versus Battery Current, as there was a large lag after the max 349 and some current draw of 50-100amp from battery.
Battery current - The present DC current at battery voltage, pretty close to what BMS should read if you don't have any other battery loads on. Can change very quickly, faster than the monitoring output can display. Negative values should be Regen current.
Controller/motor current- The AC current to the motor, at whatever AC voltage and switching frequency is happening at that split second. Speed/load/switching voltage dependent, more complicated. Also happening faster than can be displayed. I use this more as reverence for diagnosing shuddering slow/stopped motor syndrome or encoder issues.
Any live or PC logged values are subject to delays from communication speed restrictions.
Also, does re-gen breaking settings play a role? The motor in free gear should not re-gen and I currently have no switch on this. I actually just noticed that re-gen appears to be turned on and to exclude this from being a problem I would like to turn re-gen off for the time being to not complicate things.
Mashed up settings in any place can play a role, turning off regen may help narrow it down. One thing at a time though and try to get the problem to repeat.
I spun my motor on the bench and saw small negative current blips when letting off throttle due to inertia, your flywheel is capable of the same.
At 40 seconds the controller lost communication.
Is this normal? Does the dongle lose its comm lights and your computer disconnect during a fault? Please explain a bit of this.