Figured I'd post kind of a build/repair log here for the internal Leaf 1500W pictures, if anyones interested in the pictures and not a story or both, something for everyone
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Overview of this post
- Trying to figuring out the Turn Count and Strand Count of the hand written markings. Links to that info.
- Lots and lots of internal pictures of the Leaf 1500, stator, laminations, wire axle exit, magnets and drive side cover plate, hub markings. Yes its a rear hub on the front of a fat bike.
- Take note: After about 1.5-2yrs of lots of use (Riding everyday) not a power house at 36V 35A controller using 36V unknown A and Ah, and yes I am using a 52V 40A Grintech with BMS so yes a LVC. But its hauling 375lbs of my body weight, now its 315lbs for 6-8 month diet.
- Actual Repair of phase wires I will post tomorrow in its own post. Not using sensor wires for sensorless controller, Greentime if you must know, as above 36V 35A, e-abs.
- Helpful advice for noobs on how to take stator out of magnet ring, not needing a 3 prong puller.
- What wire gauge the phase wires are.
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Just took the stator out.
I have to deal with the frayed phase wires as the electrical tape just isnt enough anymore.
Dealt with a flat, brand new hardly used Kenda thorn proof with the rim hole slicing a hole in the stem. Took a Mastercraft rotary with a disk to slide over hole on both walls of the hole as the disk was much larger then rim hole, to get any shards protruding, then a stone bit that fit good in the hole.
Figured I'd install 3 broken spokes which you can see nice shiny new washers in the pic.
I've been riding with 3 broken spokes for months now, its a front hub so no issues other then wobbly.
If it was on the rear it wouldnt last a week with my heavy weight.
Put hub back on the fork, buttoned up the non disk side and went to disk side, was inspecting disk bolt to wire clearence and spun the hub and sparks. No good.
Took forever to unwind the stupid protective spring. Sliced back the protective covering by using one of the unused sensor wires. Snipped off my 5.5mm Hobbyking bullets on the phase wires. Took off disk. Undid cover plate, left other side on. Hit hub axle to the concrete floor, held rim down with a knee on the rim/tire at 6oclock and hand at 12, stator angled a bit and got slightly jammed so had to redo it, actually had to hit the stator axle on the other side to jam it back in place as normal, then redo the other side hitting axle to get stator out, be careful, magnets are powerful. Stator laminations should be complete out of magnet ring, with knee at 6, one hand at 12, take other hand and lift the stator up and out, no need for a 3-prong puller
Not sure what the markings mean.
I thought I bought a 5T winding but if I bought a 6T winding then thats what I would have preferred. For me with whatever turn count I have, 36V is good speed wise and 52V is to fast.
?????? ---> Copper fill strands 545 or 54.5 or 46 and Turn Count t6, or turn count 5 copper fill strands 45 ??????????
"545
t6"
or
"545
46"
https://endless-sphere.com/forums/viewtopic.php?f=3&t=66489&p=1596150&hilit=turn+count+fill#p1596150
- Enough room for 66 strands
- So 3T, 6T, and 11T have full copper fill
- 5T and 13T have 65 strands, and 4T and 8T have 64 strands. 7T and 9T have 63 strands. I don't think any of these are bad enough to avoid using the right RPM/volt for your application. I would avoid 10T with only 60 strands.
https://endless-sphere.com/forums/viewtopic.php?f=3&t=66489&p=1188156&hilit=strand#p1188156
- And yes, the 5T (13*5 / 65 strands) has one more strand than the 4T (16*4 / 64 strands).
Not sure how long I've had this Leaf 1500W for, lived its life with a 36V setup until a year ago when I bought a 52V 40A 15Ah Grintech battery, the 36V is of unknown amp discharge rate and much much less its original Ah/Wh judging by distance ridden before lvc. 36V 35A controller, motors gotten plenty hot (by touching cover) on short hills.
Cooked the mxus 3kw back in Feb 2020 and talked about already having the Leaf 1500W then, in a post.
FYI - I just wiped the inner with water.
I have some - Sprayon EL601 RED INSULATING VARNISH - 15 oz AEROSOL - I may use.
I am lucky I didnt pop a fet in the controller.
Yeah I knew about the wire was frayed.
I just wrapped electrical tape around each phase wire. :lol:
I don't know what I am going to do with the phase wires. My first instinct was to grab some regular heat shrink that I have plenty of in different sizes but its thin wall cheap stuff.
I will buy some thicker double wall 3:1 heat shrink to shove down in there, I dont have much slack to pull the phase wires out like I did in the mxus 3kw.
By the looks of it not much slack at all, as seen in the picture below.
I may have to rewire it. Will find a post on the wire gauge.
https://endless-sphere.com/forums/viewtopic.php?f=3&t=66489&p=1554565&hilit=wire+gauge#p1554565
I will buy some short roll 12g and 14g. No ebiking tomorrow to the store for supplies, I will have to repair it right. :thumb:
14/2 marine - https://www.be-electronics.com/product_p/marine142.htm
Pico marine 12g - https://www.be-electronics.com/product_p/9012-0-44.htm
Dual wall 3:1 dunbar - https://www.be-electronics.com/product_p/3625ws3-fslash-16.htm
So I either
A) use what I have right now, thin wall 2:1 and shove it down as far as it will go and double/triple layer it. Do the repair, put it all back together and I can ride my ebike to the store to buy what I need in B for later on in time, and order C.
B) or with no ebike or regular bicycle will have to get a ride to the train and a small walk to buy some double wall 3:1 and wire for the phases. Take train back, get a ride or take the bus.
C) order some ptfe teflon wire from my source in Cali and wait. Which is out of the question.
I know Home Depot/Lowes has a spring I can slip on the new wire for added protection.
3/8 and I see a 1/4 and 1/2
https://www.lowes.ca/product/gate-hardware/hillman-8-38-in-utility-extension-spring-246638
https://www.grainger.ca/en/category/Extension%20Springs/Springs/c/16633?type=cp&q=Utility+Extension+Spring&searchBar=true&nls=NLSAA_8-1&code=%3E=70%
https://greggdistributors.ca/search?q=Extension%20Spring&resp_group=Default,Variations,ItemProperties
Interesting, I did not notice the silicone and heat shrink at the wire entrance on axle.
Also the sensor wires are cut and in the axle. Never used them anyways.
Snapped some more pictures
This picture is insteresting. When I pulled the stator out of the magnet ring, 3 pieces of thin card cardboard fell out. I think it must be protection on the hall sensor pcb board. If I remember I will snap some pics of that, its out in the garage. Actually looking closer with a magnify glass those thin cardboard pieces are most likely slotting material that fell out. Without the magnify glass I couldnt see much, bad eyesight, but magnifine glass reveals there is paper/insulation U shape material wrapping around the windings and a card board piece on top for each slot.
Color of winding looks good and healthy. :thumb:
No distinct smell from a foot away, very slight odor up close.
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Edit
Ok so I just snipped the wire off as far into the axle as I could and they slipped out nice.
I then took out the silicone and heat shrink at the axle wire entrance as the wire was binding on it trying to slide it through.
I have a bunch of spare wires, 10awg silicone is to big for 3 wires. 12awg in silicone and regular is to big. I have 14/2 (in the yellow cable insulation, 2 wires are red and black) as seen in the pics to compare stock phase wires to the 14/2 wires) that looks the same as the Leaf 1500W phase wires.
Yellow Leaf phase wire is the top one, in the pic.
I decided to reuse the stock wires. Perhaps not the best practice, as moisture crawls up into the wire as shown in Justins old video of water ingress. So will have to ponder that one.
To late now, need to solder the phase wires tomorrow.
Might try to find some 13g wire if it exists, order it for next time the hub is opened up.
13g does exist in magnet wire.
Extra pics will be all attached for now, until edit tomorrow.
:wink:
First pic of frayed ends cut by axle and disk bolts.
Which reminds me I have to take a rotary tool with stone grinder to the axle entrance and exit.
Undo the sense wrap job and just zip tie so sense dont get damaged insulation.
Its a wire to wire solder job on the phases, lots and lots of heat shrink and proper wire management.
edit - So I will keep all my ramblings in this post for the Leaf 35H "1500W"
I've added more pics, made pic comments to all the pictures.
I have a digital caliper, typical caliper mine is Mastercraft from Canadian Tire.
Sense wire is 0.95mm O.D. with insulation, wire is 0.62mm. Probably squished the wire in a bit.
Phase wire is 2.89mm O.D. with insulation, wire is 2.24mm.
Bearing # @ 12 o'clock W 8 Z @ 6 o'clock 6204-RZ with an 01 @ 3 o'clock.
Measures 19.70mm ID caliper depth gauge is close enough 47.64 OD (brown ring) angling caliper was a bit off so yeah 47mm
W8Z 6204-RZ 01 - https://www.fagbearing.cc/SKF-bearings/6204_RZ_SKF_55004.html
For all you Amazon gamers out there - https://www.amazon.com/Replacement-6204RZ-Roller-Skating-Bearing-47x20x14mm/dp/B00N3Y0VWC
8 cover plate bolts
Total length 14.91
12.7mm is thread length measured without washer
Lamination width is 34.91mm which is a 35H. Not bothering to count the # of laminations.
More random measurements for future reference.
Total width of laminations plus both sides with winding wire is 47.49mm
axle flat to end of axle on hall sensor pcb side is 33.15mm
wire exit side is 30.36mm
Problem using old wire is the flux core solder doesnt spread and shine when you try to join wire together because of the moisture wicking up the conductor when it was in use and fouling the conductor surface so solder doesnt bond good enough for my liking. Its got to be a solid connection and I tried twice and its a no go. I used the side of the 18" wire furthest away from the damaged axle exit. So yes, the stock wire has a more solid insulator so I dont know if I want to go ahead with my 14/2 because it measures 2.15-2.20mm vs stock phase wires @ 2.24mm with stiffer strands.
I will be hooking up brand new wire straight to the windings.
edit
ok I said frock it and went with some 14/2 wire, just cant solder the old wire due to moisture wicking. Theres probably a 0.15mm difference in conductor diameter, now smaller. I need to find whatever high heat winding wrap Leaf used or find high heat shrink wrap. There's gotta be something out there.