Custom Bike Electrical Issues

[Ryzen]

I think I might have fried one of my motor controllers when I plugged my battery into it (the 48-72V 1500w one). I am aware in the image the power + and - are backward but I connected them correctly. There was a big spark when I touched the positive leads and it never made my motor turn when using the throttle with all of my wires connected correctly. I have a new controller and was looking for advice to ensure I don’t fry a second one (VEVOR). Safety of my setup aside is there anything I am missing or a way to prevent welding my fuses to my wires when I connect them? I attached images of my setup. Big thank you to anyone who tries to help in advance!

 

[Ryzen]

Colours **never** match up.

Most factories they just grab whatever spools are handy, colors change mid run

That is very good to know, I have a homemade motor at home that is probobally outside the scope of the current goal. Would this motor here be a good option to re-test all of my connections? https://www.amazon.com/yuandai-Elec...mzn1.fos.f5122f16-c3e8-4386-bf32-63e904010ad0

I'll post a video of these instructions left by E-HP, with both motors if that is a good option for a temporary purchase.

Matching color is not a reliable way of making sure things are wired correctly, unless, sometimes, you bought all components in a kit.

Nothing it going to work if you don't run the self learning routine by connecting the white self learning wires (with the wheel off the ground), and letting the self-learning do it's thing; then unplug when done. The throttle should work after that.

If you are running sensorless, you need to unplug the hall wire connector.

 

[Ryzen]

Just like my girlfriends Alfa Romeo 85 sprider from factory. That car stop me working on cars.

I
would put a precharge resistor on POS. side and plug in before main POS. A controller can take a hard start till the caps blow up 72v.

Sorry if this is a dumb question but what does POS stand for, and would you happen to have an example of a precharge resistor or would the one from amberwolf be what you are referencing?

Do the resistors need to be on the positive side?

However, they need to be able to handle the total power dissipation (watts) created during precharge. Ohm's law and Watt's law will help you calculate what you need.

Let's say you have a 200ohm resistor. At connection, it has 84v across it. 84v / 200ohms = 0.42A. 84v x 0.42A = 35.28W. So for that initial burst, you'd need a resistor capable of dissipating at least 35W of heat. LIke these 50w resistors:
https://www.amazon.com/LM-YN-Wirewound-Electronic-Industrial/dp/B076W87ZT8

 

[E-HP]

Colours **never** match up.

Most factories they just grab whatever spools are handy, colors change mid run

That is very good to know, I have a homemade motor at home that is probobally outside the scope of the current goal. Would this motor here be a good option to re-test all of my connections? https://www.amazon.com/yuandai-Elec...mzn1.fos.f5122f16-c3e8-4386-bf32-63e904010ad0

I'll post a video of these instructions left by E-HP, with both motors if that is a good option for a temporary purchase.

Matching color is not a reliable way of making sure things are wired correctly, unless, sometimes, you bought all components in a kit.

Nothing it going to work if you don't run the self learning routine by connecting the white self learning wires (with the wheel off the ground), and letting the self-learning do it's thing; then unplug when done. The throttle should work after that.

If you are running sensorless, you need to unplug the hall wire connector.

some youtube videos using the self-learning/study function:
https://youtu.be/_3ytZkqAB2g?t=274
https://www.youtube.com/watch?v=nuiNmyTZmXQ
https://www.youtube.com/watch?v=Zvhr8pDybJs

 

[Ryzen]

Colours **never** match up.

Most factories they just grab whatever spools are handy, colors change mid run

That is very good to know, I have a homemade motor at home that is probobally outside the scope of the current goal. Would this motor here be a good option to re-test all of my connections? https://www.amazon.com/yuandai-Elec...mzn1.fos.f5122f16-c3e8-4386-bf32-63e904010ad0

I'll post a video of these instructions left by E-HP, with both motors if that is a good option for a temporary purchase.

Matching color is not a reliable way of making sure things are wired correctly, unless, sometimes, you bought all components in a kit.

Nothing it going to work if you don't run the self learning routine by connecting the white self learning wires (with the wheel off the ground), and letting the self-learning do it's thing; then unplug when done. The throttle should work after that.

If you are running sensorless, you need to unplug the hall wire connector.

some youtube videos using the self-learning/study function:
https://youtu.be/_3ytZkqAB2g?t=274
https://www.youtube.com/watch?v=nuiNmyTZmXQ
https://www.youtube.com/watch?v=Zvhr8pDybJs

Thank you for those guides, they were very helpful!

While I wait for the proper motor and controller to come in here is a terribly done video with all of the information I have for the current setup. When the motor controller and proper motor arrive I will try with them as a control group. If there are any questions or suggestions ill get back with you to as soon as I can and answer to the best of my ability! https://youtu.be/5QSD-7c6gzo

Just to make sure, I can just move a wire to the middle of the current pack to draw 48v for the new kit that is coming?
Please correct me if I am wrong!

Thanks again for all the help!

 

[docw009]

Thanks for answering the polarity question, Your picture seemed to show the probes in the meter were proper and not reversed, but I'll take your assertion that you know red is +81V,

Your video show you trying to run an alternator. That's new.