CAPCur error and burned up fuses on MC board

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Scotter
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As many are aware there are a couple of fuses that like to fail on the MC board. This happened to one of my Vectrix VX-1 scooters (blue 2008 model). So I managed to get the fuses (tricky bit to do believe me!), replaced the ones on the MC board and it works. These are the little black box fuses marked "GTT" 250V 40A on the motor controller board. Typically the two just below the negative terminal; you have to remove the cable to see them clearly. If the letters are brown (not white), then the fuses are fried, or about to be. This triggers the CAPCur error code on the dashboard (but not always!).

Seeing that other owners have had this issue too, I ended up getting extras from the manufacture and I'm making them available for sale. blah blah blah, fixed the bikes, blah blah blah... you know the drill.

Here's the clincher... The demand is increasing! So far I've sold 60 fuses. (people sometimes buy extras), but that's at least 15 scooters the needed repair.

So this is a little worrysome -- what is causing these fuses to blow up? My scooter's previous owner lived in a very hot region, some of the batteries were bloated, and he said he did a lot of regen braking just before the scooter died. he said the scooter was never opened up by anyone, so it could not have been improper ICL procedure when hooking up the batter, or was it? I see indications the scooter was serviced internally at one point. So was it an improper ICL usage (if any at all) that damaged the fuses leading to eventually failing?

Any theories? Sure it's good for the business of selling fuses, but that's not my goal. I don't want to have to repair my scooter(s) again, and I certainly do not want any other owners to have to buy/install fuses multiple times.

Scotter

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--Scotter and his scooter
2007 Vectrix VX-1 Maroon
2007 Vectrix VX-1 Silver
2008 Vectrix VX-1 Blue
2008 Vectrix VX-1 Silver
Other EV projects in the works

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MEroller
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Re: CAPCur error and burned up fuses on MC board

IMO that is always the FIRST question that should ba asked when a fuse blows or a circuit braker trips: WHY could it have blown?

With the immense complexitiy of the VX1 someone at some point in time must have rather carefully and/or prudently layed out and specifically chosen these fuse sizes for this location on the motor controller board. Before suspecting brutal battery reconnection it should be analized which currents actually flow through these fuses. I assume that due to the fault name it actually IS battery current that goes through these fuses, before it reaches the input capacitors? Then of course failure to use inrush current limiting upon battery reconnection COULD be a contributing factor.

However, this greatly depends on the time constant of these fuses - are they of the fast, medium or slow type, i.e. how long does a certain overlaod take to blow them? Failure of using an ICL-device (what a sophisticated name for a simple light bulb :-) upon battery reconnection will only blow a fast fuse, as the current peak quickly diminishes. If these fuses however are of a medium or slow type, then inrush current will be highly unlikely to cause their untimely demise, and there must be a more long-lived current overload, the source of which would have to be examined more closely.

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Mik
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Re: CAPCur error and burned up fuses on MC board

Considering that the main MC fuse was "upgraded" from 125A to 200A rating, it might be that other fuses were initially also incorrectly chosen.

I do not know if the new 200A MC fuse value has been chosen based on electrical engineering principles, or because the fuse failures were bringing Vectrix Corp. down. I replaced my 125A MC fuse with a 150A fuse long before the official 200A upgrade was recommended, and this 150A fuse has never failed.

We need someone to have a detailed look at the newer MC boards, or at a MC board that had the capacitor fuses repaired by Vectrix, to see what fuse they use as replacements.

Mik

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Scotter
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Re: CAPCur error and burned up fuses on MC board

I haven't heard of anyone having Vectrix repair the MC boards and returning to the customer -- has anyone else? Note: when I ordered the GTT fuses the max amperage in the catalog is 35A. I requested 40A. They said they had leftover stock from a larger order... hmm wonder who made that order...? ;-) They didn't say if the part is now normally stocked item or still limited stock (my Chinese isn't very good).

The 125amp main fuse on my MC board showed burn marks on the terminals, and was slightly discolored, but was still working and no unusual resistance. But I replaced it anyway. 200A maybe too high of a rating to protect the MC board. That is concerning. Hate to blow it up again and not be repairable.

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--Scotter and his scooter
2007 Vectrix VX-1 Maroon
2007 Vectrix VX-1 Silver
2008 Vectrix VX-1 Blue
2008 Vectrix VX-1 Silver
Other EV projects in the works

kingcharles
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Re: CAPCur error and burned up fuses on MC board

Perhaps the MC designers at Parker could help with answers. If they kept all the documentation of course...

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LCJUTILA
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Re: CAPCur error and burned up fuses on MC board

I believe the problem is the proximity of the thick wire that attaches to the post next to the fuses that keep blowing. When that wire is installed it runs directly over the fuses. The fuses get hot on there own and the added heat from that wire which occurs when the bike is used sportingly causes them to blow. This would explain the bike operating normally when the fuses are replaced even though no other change was made. If the problem were truly electrical you would just reblow the fuse since you did not find and repair a short. This would also account for the discoloration on the outside of the fuse and the fact that the discoloration occurs more on the fuse that is closest to the post. That is where the wire would be closest to the top of the fuse and at its hottest.
I would look at putting a spacer/washer under the wire where it attaches to the post to raise it up and away from the fuses. I would possibly reroute the wire away from the fuses and/or insulate it.

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LCJUTILA

Scotter
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Re: CAPCur error and burned up fuses on MC board

how about adding a heatsink onto the fuses -- secured by the negative terminal stud. Doubles as a spacer as suggested? If the cable is getting hot, then it could use some cooling tool There are heatsinks that can be attached to the cables as well.

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--Scotter and his scooter
2007 Vectrix VX-1 Maroon
2007 Vectrix VX-1 Silver
2008 Vectrix VX-1 Blue
2008 Vectrix VX-1 Silver
Other EV projects in the works

Tampy
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Joined: 08/17/2016
Points: 3
Re: CAPCur error and burned up fuses on MC board

Hi scotter
I m looking to buy and replace those fuses on the mc board ,
So if you have some for sale , that would be great.
.

Tampy
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Joined: 08/17/2016
Points: 3
Re: CAPCur error and burned up fuses on MC board

Hi scotter ( and everyone else)
I m looking for the damn fuse to buy and replace , replaced the Heat sensors , but now when I turn the key , nothing , dashboard is not responding . Same when I plug in to charge , nothing .... Any ideas what could it be .?
Thanks for your post by the way !

R
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Joined: 06/18/2009
Points: 1741
Re: CAPCur error and burned up fuses on MC board

ut now when I turn the key , nothing , dashboard is not responding . Same when I plug in to charge , nothing .... Any ideas what could it be .?

Check battery voltage... Maybe it is too low

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