VESC Setup &
Motor Calibration

The VESC (Vedder Electronic Speed Controller) is the motor driver used in all ECE/MAE 148 robots. It controls the BLDC (Brushless DC) drive motor and the servo motor used for steering. Before beginning setup, you must understand the hardware variants and safety requirements — choosing the wrong firmware version can permanently damage your VESC.

VESC Hardware Versions in This Class

There are multiple VESC hardware variants used across different semesters. Identifying yours correctly before flashing firmware is critical — flashing the wrong firmware will break your VESC.

Gather all hardware listed below before starting. Using the wrong battery or cable during a firmware update can damage the VESC.

The entire class uses the same version of VESC Tool to keep firmware versions consistent between robots. Using a different version may produce incompatible firmware builds or missing firmware files (such as VESC_servoout.bin for legacy 4.x hardware).

1

Download the Class-Provided VESC Tool

Get the VESC Tool version specified by your instructor from the class Google Drive folder linked below. This folder contains the exact version used in class for both VESC 6.x and VESC 4.x hardware.

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Class VESC Tool — Google Drive Download

Download the class-provided VESC Tool from the shared Google Drive folder:

🔗  Open VESC Tool Class Drive Folder

VESC Tool — Direct Drive Link (copy & paste)COPY

https://drive.google.com/drive/folders/1m_gqcIWwaCzV3y3raU1FFiEpCyf3rYPi?usp=sharing
# Download the binary for your OS from this shared folder

VESC 4.x legacy — VESC Tool v2.03 (fallback)

https://github.com/rpasichnyk/vesc_tool/releases/tag/v2.03
# Download the binary for your OS from this release page

2

Install and Launch VESC Tool

On Windows, run the installer. On macOS, drag the app to Applications. On Linux, extract the archive and run the AppImage. Launch the tool and dismiss any "newer version available" prompts.

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Fig 01 — Version Warning Popup

A dialog saying "A new version of VESC Tool is available" with an OK button. Click OK to dismiss — do not follow the upgrade link.

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Dismiss Version Warnings

If you see a popup saying "A new version of VESC Tool is available", click OK to dismiss it. Do NOT click the link to download a newer version unless instructed by the TA.

After connecting, identify your hardware version in the Firmware panel. VESC 6.x devices (including VESC EDU) should be updated to firmware v6.00 using VESC_default.bin. This ensures your VESC runs the same software as all other robots in class.

How to Identify Your Hardware Version

When connected in VESC Tool, look at the bottom-left status area and the Firmware panel. You should see one of the following hardware identifiers:

1

Open the Firmware Panel

In the VESC Tool left navigation sidebar, click Firmware. You will see a list of hardware versions, each paired with a firmware file. Find your hardware version in the list (EDU or 60).

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Fig 04 — Firmware in Sidebar

VESC Tool left sidebar with the Firmware menu item highlighted in blue.

2

Select Your Hardware Row and Click Update

Select the row matching your hardware version (e.g., EDU → VESC_default.bin). Click the single download arrow button labeled "Update firmware on the connected VESC". Do not click "↓ All" — that flashes all connected VESCs and is not needed here.

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Fig 05 — Hardware Row Selected

Firmware list with hardware version "60" highlighted and VESC_default.bin shown in the firmware column. Select your matching row.

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Fig 06 — Firmware Toolbar Buttons

Toolbar with a single download arrow (↓) and a "↓ All" button. Use the single arrow only.

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Fig 07 — Download/Flash Button

The large download arrow button used to start the firmware upload.

3

Confirm the Firmware Overwrite Warning

A dialog appears: "Uploading new firmware will clear all settings in the VESC firmware and you have to do the configuration again. Do you want to continue?" Click YES. All settings will be cleared — this is expected. You will reconfigure everything during the motor detection steps that follow.

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Fig 08 — Overwrite Confirmation

Dialog asking to confirm firmware overwrite. Click YES to proceed.

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DO NOT Disconnect During Upload

After clicking YES, do not disconnect power or the USB cable until you see "Upload done" in the status bar. The VESC will automatically reboot within 10 seconds after the upload completes. Do not touch anything until the reboot finishes.

4

Verify the Successful Upload

After the VESC reboots, reconnect in VESC Tool. The status bar should show the new firmware version. For VESC EDU, you will see Fw: v6.00, Hw: EDU. For a standard VESC 6.x, you will see Fw: v6.00, Hw: 60.

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Fig 09a — Upload Done Dialog

Dialog: "The firmware upload is done. The device should reboot automatically within 10 seconds. Do NOT remove power before the reboot is done." Click OK.

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Fig 09b — Upload Done Status Bar

VESC Tool bottom status bar showing "Upload done" text.

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Fig 10 — Successful Firmware Update

Firmware panel after a successful update showing status: Fw: v6.00, Hw: EDU, Status: STABLE.

Expected status after a successful VESC 6.x firmware update

Fw: v6.00, Hw: EDU
Paired: false, Status: STABLE
HW Type: VESC, Phase Filters: Yes
NRF Name: No, Pin: No

# Status bar shows: "Upload done" then VESC reboots automatically

VESC 4.x hardware requires a special firmware called VESC_servoout.bin. This firmware repurposes one of the VESC's PWM input pins to work as a PWM output, allowing the VESC to drive the steering servo motor. The latest versions of VESC Tool do not include this firmware file — you must use VESC Tool v2.03, which ships with firmware v4.2 containing VESC_servoout.bin.

https://github.com/rpasichnyk/vesc_tool/releases/tag/v2.03

https://github.com/RacecarJ/vesc-firmware
https://github.com/RacecarJ/vesc-firmware/tree/master/firm
# Look for: VESC_servoout.bin targeting HW 4.12

After flashing VESC_servoout.bin on your VESC 4.x, continue with Section 7 (Cable Connections) and follow the same motor detection steps as VESC 6.x — the FOC wizard procedure is identical for both hardware versions.

The FOC (Field-Oriented Control) wizard automatically measures your motor's resistance, inductance, and flux linkage, then configures the VESC with optimal control parameters. FOC provides smoother, more efficient motor control than older methods. Running this wizard replaces manual parameter entry and produces accurate, motor-specific calibration values.

1

Navigate to Welcome & Wizards → Setup Motors FOC

In the VESC Tool left sidebar, click Welcome & Wizards. Then click the Setup Motors FOC button. A dialog will appear asking about loading default parameters.

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Fig 12a — Wizards Menu

VESC Tool sidebar with "Welcome & Wizards" highlighted in blue.

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Fig 12b — Setup Motors FOC Button

The large "Setup Motors FOC" button in the wizard panel.

2

Load Default Parameters — Click YES

A dialog appears: "Would you like to restore this VESC, and all VESCs on the CAN-bus (if any), to their default settings before proceeding?" Click YES. This ensures a clean starting state and prevents any old, misconfigured settings from interfering with the detection.

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Fig 13 — Load Default Parameters

Dialog asking to restore default settings. Click YES.

3

Select Motor Usage: Generic

On the USAGE tab, select Generic. Do not select a specific application profile — Generic applies appropriate FOC parameters for a wide range of BLDC motors without making assumptions about the load type.

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Fig 14 — USAGE Tab

FOC wizard USAGE tab with the "Generic" option highlighted in blue.

4

Select Motor Type: Medium Inrunner (~750 g)

On the MOTOR tab, select Medium Inrunner (~750 g). An inrunner motor has the spinning rotor on the inside (unlike an outrunner where the outer shell spins). This preset sets appropriate current limits and FOC tuning parameters for the class RC car motors (such as the XeRun 3660 G2 and similar sensored inrunner motors in the 700–800 g range).

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Fig 15 — Motor Type Selection

FOC wizard Motor tab with "Medium Inrunner (~750 g)" highlighted in blue.

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Why Medium Inrunner?

Using the wrong motor size preset can cause jerky performance or trigger over-current faults. The Medium Inrunner preset matches the physical and electrical characteristics of the motors in this class. If you are unsure whether your motor qualifies, ask a TA to confirm before proceeding.

Correct battery configuration is critical for safety. The VESC uses these settings to calculate low-voltage cutoff thresholds — the point at which it shuts down to protect the battery. Using the wrong cell count can result in either premature shutdowns (annoying but safe) or, more dangerously, allowing the LiPO/LiIon battery to over-discharge, which causes permanent cell damage and creates a fire risk.

1

Set Battery Type, Cell Count, and Capacity

In the Battery tab of the FOC wizard, set Battery Type to BATTERY_TYPE_LIION_3_0__4_2. Set Battery Cells Series and Battery Capacity to match your physical battery (see the table above).

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Fig 16 — Battery Tab

FOC wizard Battery tab. Set Battery Type to BATTERY_TYPE_LIION_3_0__4_2 and enter your cell count and capacity from the battery label.

Battery settings in the FOC wizard

Battery Type:         BATTERY_TYPE_LIION_3_0__4_2

# ECE/MAE 148:
Battery Cells Series: 3        # 3-cell LiIon/LiPO battery
Battery Capacity:     3.000 Ah  # As printed on the battery label

# DSC 178 / Racing robots:
Battery Cells Series: 4        # 4-cell LiIon/LiPO battery
Battery Capacity:     4.000 Ah  # As printed on the battery label

2

Click Next to Continue

After setting the battery parameters, click Next to advance to the motor parameter configuration page.

The VESC needs accurate motor parameters to calculate correct RPM readings and speed control. The most important value is the number of magnetic poles on your motor — this directly affects all speed calculations.

Finding Your Motor's Pole Count

You must look up the pole count for your specific motor model. The pole count refers to the number of magnetic poles on the rotor (the spinning part inside the motor). It is not the same as the number of stator slots (the stationary coil slots on the outside). For the class example motor:

# Motor part number: XeRun 3660 G2
# Manufacturer link:
https://www.hobbywingdirect.com/products/xerun-3660-g2-sensored-motor

# Spec: "innovative 14-pole-28-magnet staggered pole rotor"
# Pole count to enter in the VESC wizard = 4
# (Always verify against YOUR motor's datasheet — do not guess)

1

Set Gear Ratio: Direct Drive

In the wizard, select Direct Drive for gear ratio. The class RC cars use a direct-drive configuration where the motor connects to the drivetrain without an additional software-level gear ratio adjustment.

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Fig 17 — Gear Ratio

FOC wizard Gear Ratio section with "Direct Drive" selected (blue checkmark).

2

Set Number of Motor Poles

Enter the pole count for your motor. For the XeRun 3660 G2 and most class motors, this is 4. Always verify against your motor's datasheet before entering a value.

Motor pole count entry

Motor Poles: 4   # Verify against YOUR motor's datasheet

3

Set Wheel Diameter: 100.00 mm

Set the wheel diameter to 100.00 mm. This is the standard wheel size used on the class RC car platform. Accurate wheel diameter ensures that speed readings in m/s are correct when using the Robocar software framework later.

Wheel diameter setting

Wheel Diameter: 100.00 mm   # Standard class RC car wheel

The FOC motor detection wizard in the previous section measures motor parameters (R, L, λ) but does not configure the hall sensors — that is a separate step. Hall sensors are small magnetic sensors mounted inside the motor that tell the VESC exactly where the rotor is positioned at any given moment. This is especially important at low speeds where sensorless estimation is unreliable.

Why Hall Sensor Detection Matters

Without correct hall sensor calibration, the motor operates in sensorless mode below the Sensorless ERPM threshold (ERPM = Electrical RPM, which equals the motor's pole count multiplied by the mechanical RPM). Sensorless operation at low speeds produces stuttering and jerky starts. With hall sensors properly mapped, the VESC transitions smoothly from sensored (low-speed) to sensorless (high-speed) operation as the motor spins up.

1

Navigate to Motor Settings → FOC → Hall Sensors Tab

In the VESC Tool left sidebar, click Motor Settings → FOC. In the tab bar at the top of the FOC panel, click the Hall Sensors tab. You will see the Sensor Mode dropdown and the Hall Table entries.

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Fig 21 — Motor Settings FOC Panel

Motor Settings → FOC panel with tabs for General, Hall Sensors, and other options. Select the Hall Sensors tab.

2

Verify Sensor Mode is Set to "Hall Sensors"

The Sensor Mode dropdown should read Hall Sensors. If it shows Sensorless or Encoder, change it to Hall Sensors. This setting tells the VESC to use the connected hall sensor cable for rotor position feedback at low speeds.

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Fig 22a — Sensor Mode: Hall Sensors

Large display showing "Sensor Mode" on the left and "Hall Sensors" on the right.

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Fig 22b — Hall Sensors Button

The Hall Sensors selection button/badge.

Sensor Mode setting

Sensor Mode: Hall Sensors   # Must be set to this value
# NOT: Sensorless
# NOT: Encoder

3

Run Hall Sensor Detection

At the bottom of the Hall Sensors tab, find the Detect Hall Sensors section. Leave the detection current at the default (10.00 A is appropriate for class motors). Click Start Detection. The motor will spin slowly while the VESC reads and maps the hall sensor pattern for every rotor position.

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Fig 23 — Hall Table Before Detection

Hall Sensors tab before running detection — all Hall Table values show 255 (unconfigured). Click Start Detection to populate the table.

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Wheels Will Spin During Detection

The motor rotates during hall sensor detection. The robot must be on the stand with all wheels clear before clicking Start Detection.

4

Verify Hall Table Values and Click Apply

After detection, the Hall Table entries (Hall Table [0] through [7]) will be populated with numbers. These values are unique to your motor and its wiring — they will differ from any examples shown here. Click Apply to accept the detected values. A value of 255 in a table slot means that state is unused; this is normal for slots [0] and [7].

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Fig 24 — Hall Table After Detection

Hall sensor table after detection — Hall Table [1]–[6] are populated with unique values. Your values will differ from this example.

Example hall sensor detection output (your values will differ)

# This is an EXAMPLE — do not manually enter these values
# Your detected values will be different, and that is correct

Sensorless ERPM:          4000.00
Hall Interpolation ERPM:  500.00
Hall Table [0]:           255
Hall Table [1]:           115     # ← unique to your motor and wiring
Hall Table [2]:           49
Hall Table [3]:           82
Hall Table [4]:           182
Hall Table [5]:           149
Hall Table [6]:           15
Hall Table [7]:           255
Hall Sensor Extra Samples: 1

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What Do These Values Mean?

The Hall Table maps the six commutation states of the BLDC motor to the three hall sensor signals. Values 0–5 represent valid states; 255 means that state is unused. If all values remain 255 after detection, the hall sensor cable is not connected correctly — re-seat the connector and try again.

5

Write Motor Configuration

After clicking Apply, save the hall table to non-volatile memory by clicking the ↓M (Write Motor Configuration) button in the toolbar. Without this step, the hall sensor mapping will be lost the next time the VESC is powered off.

Save hall sensor configuration

# Apply the detected values, then click ↓M in the toolbar
# Confirmation: "Motor configuration written" — hall table saved

Troubleshooting Hall Sensor Detection

By default, the VESC's PWM/servo pin is configured as an input (for receiving commands from an RC receiver). For the class robot, we need it as an output so that the VESC generates the PWM signal that drives the steering servo motor. This requires enabling "Servo Output" in the App Settings and writing the configuration.

1

Navigate to App Settings → General

In the VESC Tool left sidebar, click App Settings → General. Make sure you are in the APP section, not the MOTOR section — look for the APP badge next to the menu items.

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Fig 25 — App Settings Sidebar

VESC Tool sidebar showing App Settings > General highlighted in blue with an APP badge.

2

Enable Servo Output

Find the Enable Servo Output setting and change it from False to True. This repurposes the VESC's PWM servo pin from an input to an output, allowing the VESC to send steering commands to the servo motor.

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Fig 26 — Enable Servo Output

App Settings General panel with "Enable Servo Output" set to True.

App Settings → General — enable servo output

Enable Servo Output:  True    # ← Change this from False to True

3

Write App Configuration

Click the ↓A (Write App Configuration) button to save this change to non-volatile memory. Without writing, the Enable Servo Output setting reverts to False the next time the VESC is powered off.

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Fig 27 — Write App Config (↓A)

The Write App Configuration (↓A) toolbar button. Click this to save the Enable Servo Output change.

Save the servo output setting

# Click ↓A in the toolbar after enabling servo output
# Confirmation: "App configuration written"

4

Test the Steering Servo

Navigate to App Settings → General → Controls tab. You will see a Servo Output slider. Drag the slider left and right — the front wheels should turn left and right accordingly. Use the Center button to return the servo to the neutral (straight) position.

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Fig 28 — Servo Output Slider

App Settings General Controls tab showing the Servo Output slider and Center button. Drag the slider to test steering.

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Wheels Not Responding?

If the front wheels do not respond to the servo slider: verify the servo cable is connected to the VESC's PWM output port; confirm Enable Servo Output is True and the app configuration was written; and check that the servo motor is receiving 5 V power from the VESC's BEC (Battery Eliminator Circuit — a built-in voltage regulator that provides a steady 5 V output for the servo).

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Setup Complete

When the servo slider produces smooth left/right front wheel steering, the VESC setup is fully complete. You can now move the USB cable from your laptop to the Raspberry Pi's USB port and proceed with the Robocar software setup.

Firmware & Connection

Motor Detection

Hall Sensors

Servo Steering

Battery & Power

UCSD Jacobs School of Engineering — ECE/MAE 148 Intro to Autonomous Vehicles