Motor Blown Up?

[stever1957]

Hello again.

I suppose when the motor starts to behave in a juddery fashion, then smoke comes out of it and then it stops working, but tries to, that means it's done for?

 

[Woosh]

It could be a bad contact on one if the phase wires, the thick green, yellow ond blue wires. Check first that the motor cable is pushed in all the way up to where the lip of the female connection on the motor side comes up to the circle on the controller side.

 

[stever1957]

It could be a bad contact on one if the phase wires, the thick green, yellow ond blue wires. Check first that the motor cable is pushed in all the way up to where the lip of the female connection on the motor side comes up to the circle on the controller side.

Thanks for that.

I'll go and check that in the next half hour.

 

[stever1957]

Okay.

The smoke wasn't coming from the motor, it seems.

The connector from the controller side is melted, with a pin from one connector now stuck in the hole of the other.

 

[Nealh]

Cut the connectors off and solder the opposing wire directly together , not forgetting to slide a bit of heat shrink along the wire first to insulate the join.
Bullet connectors are known for fusing togehter with phase wires.

 

[stever1957]

Cut the connectors off and solder the opposing wire directly together , not forgetting to slide a bit of heat shrink along the wire first to insulate the join.
Bullet connectors are known for fusing togehter with phase wires.

There is a delicious logic to your solution which, I fear, I might not have arrived at before I became mummified.

I've cut off the connectors, stripped the wires and will get some heat-shrink before continuing.

The wires are: red, blue, green, black, white and yellow.

I imagine they must all be connected?

 

[stever1957]

Well, I connected all of the wires temporarily, by just twisting them together.

The motor is fine and I rode the bike around the block.

I just need to find a way of connecting all of these wires permanently, but so that they can be disconnected if required.

 

[Woosh]

Andy is on holiday until the end of the week. You could use WAGO blocks as a temporary solution. When he gets back, I will ask him to get in touch with you to sort our replacement connectors.

 

[stever1957]

Andy is on holiday until the end of the week. You could use WAGO blocks as a temporary solution. When he gets back, I will ask him to get in touch with you to sort our replacement connectors.

Oh, many thanks.

 

[Nealh]

Only the three thicker Phase wires Green , Blue & Yellow are the ones that carry the higher current. The other three are Hall wires which can be left as they are..

 

[stever1957]

Only the three thicker Phase wires Green , Blue & Yellow are the ones that carry the higher current. The other three are Hall wires which can be left as they are..

We are talking about the connectors at the motor?

I ask this because, when I connected them all up earlier, I found I was getting that 'juddering' again, until I noticed that the white wire had become disconnected. When I also connected the white wire, all was good.

 

[Woosh]

We are talking about the connectors at the motor?

I ask this because, when I connected them all up earlier, I found I was getting that 'juddering' again, until I noticed that the white wire had become disconnected. When I also connected the white wire, all was good.

The white wire sends speed signal. It is low power but can still cause trouble. I am sure you and Andy will devise a permanent solution .

 

[stever1957]

The white wire sends speed signal. It is low power but can still cause trouble. I am sure you and Andy will devise a permanent solution .

 

[Nealh]

It is not usual for the motor connector to melt , when faults occur they are more then often at the controller end.