rivvs said:
I tested the controller after the fire and it works fine, but the controller can not use the hall sensor from the motor it always fault an hall sensor error. It work in sensorless mode.
Is the fault due to the motor itself, or is it the same with an identical replacement motor?
Note that if you have not tuned the controller for the motor it's being used with, it may not work correctly and can have various errors (can even damage the controller or motor under some conditions).
If the fault occurs even with a motor with working hall sensors that you know works with this controller and the controller is tuned for this motor, then my guess is a connector issue at the controller itself caused by the heating during the fire, or electrical damage if the system was powered during the fire and motor phases or battery positive were shorted to hall signal wires at any point during the event, which could have damaged the inputs to the MCU (or circuitry between them) with the excessive voltage. (this damage occurs in axle-wiring-failure events on hubmotors frequently enough).
I believe the software would allow this because I have seen people using 21s with this controller.
Big difference between 21s (88.2v full) and 96v nominal, which is 26s assuming 3.7v/cell, and full voltage would be 109v assuming 4.2v/cell.
So if you don't already know that the software would allow it, and that the LVPS of the controller can handle that kind of voltage (so the LVPS doesn't fail and blow up the brain, etc), I'd recommend verifying this for certain before pursuing that kind of voltage increase, so you're not wasting money on parts that aren't needed.