I melted the Phase Wires in my Ebike!! This is how I fixed it.
Vložit
- čas přidán 14. 09. 2021
- Please check out the links below.
They are affiliate links so I will receive a few cents if you make a purchase but you won’t pay a penny extra.
Thank you for your support.
I was behaving like a hooligan and melted the phase wires in my ebike. It was my fault it happened not only because of my bad behaviour but my previous poor workmanship. In this video I try to make amends.
Irwin Wire Strippers
Amazon amzn.to/2VLVj3I
80W Soldering Iron
Amazon.com amzn.to/3AmS2XC
Amazon UK amzn.to/3zdbSDz
Ebay.com ebay.us/P2nsT9
Ebay UK ebay.us/1wIEZ4
Aliexpress s.click.aliexpress.com/e/_AnrApw
KT Sine Wave Controller/Kit
Amazon.com amzn.to/3gWCdQd
Amazon UK amzn.to/2SdaoJU
eBay.com ebay.us/asy5lJ
eBay UK ebay.us/kGcnVC
Aliexpress s.click.aliexpress.com/e/_AdA6eZ
KT LCD3 Display
Amazon.com amzn.to/3jM6cMP
Amazon.co.uk amzn.to/2Thz98t
eBay.com ebay.us/n5Wu8n
eBay.co.uk ebay.us/rZywcn
Bafang BBS01, BBS02, BBSHD Mid Drive Kit
Amazon.com amzn.to/3w51RXl
Amazon.co.uk amzn.to/3y6XWdZ
eBay.com ebay.us/39OXlW
eBay.co.uk ebay.us/ElYb7K
Aliexpress s.click.aliexpress.com/e/_9QcBHm
BBS01, BBS02, BBSHD Reprogramming cable
Amazon.com amzn.to/3d166g2
Amazon.co.uk amzn.to/3vKcqik
eBay.com ebay.us/gTDcTX
eBay.co.uk ebay.us/MJLSn2
Aliexpress s.click.aliexpress.com/e/_9QIlEd
OTG adaptor Cable
Amazon.com amzn.to/39hLOwt
Amazon UK amzn.to/3hWRSPV
Ebay.co.uk ebay.us/pSDTbC
Aliexpress s.click.aliexpress.com/e/_ADXzvK
Battery building Supplies
Cell Holders 10S ebay.us/POV3ap
Cell Holders 5S ebay.us/SZVatA
Solid Nickel strip 8mm x .15mm ebay.us/2iHNTL
Solid Nickel Strip 10mm x 0.15mm ebay.us/UZMSvA
18650 Cells
If you are looking for 18650 cells to build a battery pack here is where I buy mine. I have always used LiitoKala cells and found them to be good quality.
Note the Name brand cells are copies, they are NOT genuine but do have similar properties to the original and are still excellent batteries.
Panasonic Look alike s.click.aliexpress.com/e/_AD95VL
Samsung Look alike s.click.aliexpress.com/e/_9yZqrx
LG Look alike s.click.aliexpress.com/e/_9gG85X
LiitoKala 3400mAh 20A max s.click.aliexpress.com/e/_9xMngp
LiitoKala 3000mAh 35A max s.click.aliexpress.com/e/_9hlt97
LiitoKala 3500mAh 35A max s.click.aliexpress.com/e/_APDKu9
Also note LiitoKala have several shops on Aliexpress with slightly different names but the products are all the same.
Voilamart Ebike kit
eBay UK ebay.us/AV38FZ
Cheap Ebike Controller
ebay.co.uk ebay.us/8dPcJm
Amazon.co.uk amzn.to/3zZMoec
Amazon.com amzn.to/2UrJxKP
ebay.com ebay.us/WXDo9m
Aliexpress s.click.aliexpress.com/e/_At4yWR
Smart BMS (Bluetooth)
Aliexpress s.click.aliexpress.com/e/_9zeEQl
Amazon.co.uk amzn.to/3h799pu
Amazon.com amzn.to/3dvLXyW
eBay.com ebay.us/YOJtbD
eBay.co.uk ebay.us/PQVsBa
Vortecks VBMS App
play.google.com/store/apps/de...
Uni-T Clamp meter
Amazon.co.uk amzn.to/3h7ttWy
eBay.co.uk ebay.us/dt6YTz
Amazon.com amzn.to/3xPYdlC
Ebay.com ebay.us/BhPrqF
Aliexpress s.click.aliexpress.com/e/_9xIk0b - Jak na to + styl
Thanks Ali, for the Carpentry/Electrical lesson of the week.
Good tidings Sir .
Thanks.
the problems are usually the connectors. Just replace them with bigger one.
If you beef them wires to make them thicker your bike will run slower and box will get hot the phace wires are spacial wire that's why the Chinese yes that wire. These kits are fully tested. To make bike go faster yellow box lug connection yes thinner ones but it could cause box to get hot I've improved my power so when I get to 45mph the box gets hot but I can keep my fingers on box with out burning them. So I'm going back to thicker connectors. Another way is solder in controller shunt bars if you have three bars don't if two nip together and solder along the top it works I done that on my 32amp +2amp controller now I've got 45amp
answer simple your controller pulls 10amp to 40amp or more, u use for extension max 6amp house wire so its normal to burn only that part. if you use high amp wire like silicone 12awg or 14awg cable then you should be fine
Yip, 100% right. I was a numpty.
Hi what size lug connectors did you yes for motor and controller that's hall wires and phase lug connectors I bought of Amazon but I'm not sure if they are heavy enough I've used them the wires get warm after a couple of miles thanks colin
I don't remember what size the lugs were but just used lugs that fitted the cable. The hall wires don't carry any current so it's only the phase wires you need to worry about. I think I used 4 square mm wire for the phases.
@@alibro7512 hi thanks reply
Hi the lug phase wire connectors from motor and controller where can I buy the proper ones thanks
Different controllers come with different connectors but I usually by mine from Ebay. Just ensure they have the correct current rating and you'll be fine.
Hi what size phase connectors to use for hub motor and controller thanks. Pd can I use choc block connection if so what amps thanks
What is the watts and voltage of your bike?
Watts/Volts = Amps. It doesn't matter what connector you use so long as it is OK for that number of amps.
@@alibro7512 hi thanks for reply but I'm no forward wit your Anser it does matter yes wrong connectors and bang no bike my bike is 2000wat controller 45amp battery 52volt can tel me what you used I will be very great full thanks
@@colinwhite144 you need to buy connectors rated for the current of your controller. 2000w/52V = 40A. Allow a little extra so you need connectors that can handle 50A. The design or style doesn't matter so long as they are rated correctly.
The controller is what desides the current.
So I’ve just built a 3000w 72v e-bike, have only ridden it once for about 15 minutes but after about 10 minutes I could feel a warm but not boiling temperature coming from the controller? Is this normal with these power builds as I have a 1500w Voilamart and full throttle non stop and will literally never feel temperature from the controller? Thanks a lot
I haven't used a 3kW controller so can't speak from experience but I believe it's normal for them to feel warm but not hot. If it's too warm to keep your hand on it then something is wrong.
Maybe insufficient air flow or possibly the configuration is not correct for your motor.
Great cable tye tip
You did well making it that far into the video. 🤣
@@alibro7512 😅
Hi I've just learned my fuse from controller to battery was getting hot slight burn used 35amp fuse I bought lug connectors from Amazon there serposed to be copper with coating I scrape one connectors it's not copper can that cause that problem. Do you recommend to buy new in line fuse holder as slight marks on one spade I was going to use 50amp choc box connection they are copper if I put 40amp fuse in that might be to much I don't no what fuse you ues on 2000wat hub motor 45amp controller battery 52volt 19.5amp
A 2000W controller will draw 40A from your batteries so everything needs to be rated for at least 50A. Many on ebay and Amazon are listed at higher than they really are so you need to be careful where you buy.
Don't pick the cheapest and if possible buy from local sellers who can advise if their item is suitable.
@@alibro7512 thanks for reply my motor is 2000wat the controller that came with kit was 32+1amp used 30amp fues in had no bother the bought 45amp controller for more speed so I put in 35mph ruse controller I bought had bullet female connectors my wheel phace was lug so I bent three of them to. Make half moon and pushed in to controller bike ran OK but I never checked fuse it seemed to be OK but I thought best is to buy for both phace wires lug connectors. I've got 50amp choc box connection which are copper I had them on before I will try that again and veep check the fuse copper is better the fuse wasn't burnt it just went soft evadance of over heat thanks again
@@colinwhite144 there is no standard unfortunately so it's pot luck what type of connector you get. It's better if you can solder on the correct connectors or even solder the wires but if your method works then go with it. You don't need to over think it.
drill holes in the sides of the hub. it will cool the motor. on one side drill them near the centre on the other drill them near the outside. have a voilamart 1500watt hub that ive drilled and can put a LOT more than 1500 through it. grin technologies have a really long video with heat tests on overloaded hub motors. basically if you drill them like ive said - they dont overheat at all ever. mind you to make a motor overheat you need to put a lot of amps through it continously - this means a long uphill stretch. top speed doesn't load them as much - grin goes through all this .
It's only a 1500W controller so the motor is fine. If I replace the controller I'll do this thanks.
@@alibro7512 get a battery holder with built-in controller. Less wires & less problems = less heat
@@Free__Speech The pack was made to fit the available space.
@@alibro7512 Democracy is looking more and more like an illusion these days.
V brakes on a thousand watt motor........brave man. How do they perform?
The brakes on this bike would put you over the handle bars. They have always been good and are better than the disc brakes on my other bike.
I just don't ride it in the wet. 😉
A good V brake can be a decent Anchor ⚓
My phase wires have scorch marks and they're brand new, must get really hot, I'm only at 55v 30amps, probably because they keep coming loose so get even hotter shorting, they are simple male and female bullet connections, after seeing this and the scorch marks I'm gonna put some better rc car connections on just to be safe, sure makes a horrible juddering when you lose a phase wire
I came to a juddering halt as they all shorted. 😲
Did the phase wires shorting cause any damage to the controller or hub motor? I have done the same as you but get error 10 on my sw900 display. Any ideas ? Tia
@@johnsilvester4681 yes, it can blow the controller
I just had an issue with the voilamart 26 in front 1000 watt 48v green and blue motor to controller connector covering melting. Felt a knocking from the bike was not sure which wheel cause its dual wheel drive. The front is direct and the back is geared. Got home and opened the front controller case and saw the issue. They must have touched.The case has a digital voltmeter with temp sensor and the inside the case was 97 degrees F. i live where there is big hills.
From what I've seen myself and from others any ebike kit from China can have issues, especially if driven hard. 😉
So biger the wire last heat
Yes. bigger pipes carry more water and it's the same with wires.