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.

 

[saneagle]

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.

Solder them together. You'll probably never need to disconnect them again, and if you do, you can cut them. All that is a lot less work than ordering connectors and soldering both sides, and it'll give a much more reliable solution, and it's cheaper. Win, win, win.

 

[stever1957]

Well, while I'm waiting for my Wago connectors to arrive, I decided to connect them up. temporarily, with those white, nylon ones that you screw closed.

I decided to try connecting just the three thick wires, and lo-and-behold, it works great!

Thanks Nealh.

 

[chris_n]

Wago connectors are only good for testing. They have no mechanical cable retension and aren't designed for applications where vibration / movement is present.

 

[stever1957]

Wago connectors are only good for testing. They have no mechanical cable retension and aren't designed for applications where vibration / movement is present.

I see, thank you.

 

[Woosh]

Wago connectors are only good for testing. They have no mechanical cable retension and aren't designed for applications where vibration / movement is present.

Wago Lever-Nut Style (e.g., 221 or 222 series)

• Have cable retention via the spring or lever clamp.
• These are designed to grip the wire securely, including stranded and solid conductors.
• They are reusable and tool-free, which is part of their appeal.
• Can handle high currents (some rated up to 32A depending on model and wire gauge).

Product details


A two-way compact splicing connector with handy lever for quick and hassle-free installations. Use this pack of reusable Wago 221 connectors for solid, stranded and flexible cables.
These connectors couldn't be easier to use - simply pull the lever up, insert a stripped conductor and push the lever back down. They help you quickly install devices with higher levels of power consumption, and feature transparent housing for visual inspection.

You can use Wago 221 2 way 32A blocks if you don't have crimping tools.

 

[stever1957]

Wago Lever-Nut Style (e.g., 221 or 222 series)

• Have cable retention via the spring or lever clamp.
• These are designed to grip the wire securely, including stranded and solid conductors.
• They are reusable and tool-free, which is part of their appeal.
• Can handle high currents (some rated up to 32A depending on model and wire gauge).

Product details


A two-way compact splicing connector with handy lever for quick and hassle-free installations. Use this pack of reusable Wago 221 connectors for solid, stranded and flexible cables.
These connectors couldn't be easier to use - simply pull the lever up, insert a stripped conductor and push the lever back down. They help you quickly install devices with higher levels of power consumption, and feature transparent housing for visual inspection.

You can use Wago 221 2 way 32A blocks if you don't have crimping tools.

I see, thank you too