I am guessing the hall sensors would stop working, or the epoxy would fail before the insulation on the new wires would melt
The new sensor wires are actualy routed straight out the front of the motor so they hardly touch the windings at all. They were wrapped around in the picture just to hold the sensors in place while the glue set.
'Real Ale' (the live, non sterilized beer) is best drunk at just below room temp, about 12c to 15c so you can taste the groovy flavours! However probably most of the beer sold over here is what we call 'lager', light in colour, sterelized and served cold as kiM describes on the previous page.
The voltage in the video was 24.
I wonder if the stator lamination material is different in the new style 80-85 motors, the cogging seems to be very much less (perhaps 90% less) than the older 80-100 motor that I have. Could this account for the higher no-load current?
The lamination thickness looks to be the same, the magnets appear to be of a similar strength, airgap and geometry are similar (except of course for the 15mm shorter stator).
What modifications did you make to your 6 FET controller and how has the performance changed?
It does not matter what gap you start glueing the sensors in the stator, the important thing is that they have a 120 degree spacing (put one in every 4th gap), and that they all face the same way, I fitted mine with the chamfer facing outwards.
Phase wiring I discovered by trial and error. Use a small fuse in the supply and a current meter to prevent any fireworks
Leave the phase wires fixed, you then have maximum of 6 (or is it 9) combinations of sensor connections to play with.
If you cannot get it to run well, swap two of the phase wires over and try the sensor wire combinations again.
Just a word of caution --I have not been able to test this modified motor with any significant mechanical load yet.
If your motor is the new style with the skirt bearing, it would be interesting to measure the no-load current at max rpm
EDIT: I have since tried one of the new style 80-100 motors, no-load was 4 amps @24v (this is quite a bit less than the new style 80-85 motor