edventure
100 W
Hello Again,
If you don't want to read my history, then just read the last paragraph to see what I am contemplating doing.
First History:
I have not been on the forum for a bit. I finally had put my bike back in operation towards the end of April after multiple issues including a blown controller. Was able to get another 600 miles on it, by the middle of June until driving home late one night I hit the brakes while coming to a stop light and I heard and felt the same noise and vibration I had when the controller blew. I immediately unplugged the controller from the motor but found this did not make a difference, the motor would not roll easily, had the feeling of a stationary bike on the hardest setting. This was about 16 miles into my 20 mile ride home from work at around 11:30 PM and made an already long day much longer. I parked the bike and did not look at it until last week due to other priorities and just overall tired of working on the bike and money put into it.
I have now had enough time to cool off and am looking at my options for getting this going again, but stronger than it was before. I had purchased from Lyen what he had called a Crystalyte 5303 v2 /Phoenix Racer II motor. At the time he said it was the equivalent of an H3540 Motor. This is a rear sensored motor that could go about 36 MPH at 48V. I have a headway headquarters pack that I had put together that was a 2P16S setup 48V Nominal 30 Ah capacity. This was able to get me the 20 miles to work, charge it at work and then back in the evening, averaging high 20 MPH. I would have an elevation change of almost 1000 ft with a 3% grade maximum, but this would get the motor fairly warm by the time I made it to work. I ended up changing my block time from .2 to 2 sec in the controller settings when I got it working again in April since it would give me additional hill climbing power that really seemed to make a big difference in the overall bike operation. I know what many of you will say, "you put too much power into the motor" I agree and take full blame for that, but now I want to get it operational again and would like to have it handle these wattages 1800 to 2200W for the hour long ride into and back from work reliably.
Possible Repair Plans:
I looked into replacement motors from HPC and they recommended a H4080 or H4065 motor with the side cover drilled open, but were talking over $600.00. I contacted Lyen regarding this to see what he would recommend, and I never heard back from him, probably because he is tired of dealing with me.
I am now debating about trying to rewire the motor I have myself using an upgraded magnet wire from a company called Superior Essex. They have a product called Alex that can reliably run up to 240 deg C. http://www.eis-inc.com/Files/pdf/su...loads/superioressex/Allex_240_Magnet_Wire.pdf I would imagine this is much better than the wire that comes in the stock Crystalyte motors. I think the wire gauge that is currently in the motor is either 23 or 24 AWG, but I am not sure about this, need to more carefully measure the wire that is currently in the motor. So my possible plan would be to rewire with the higher temp magnet wire, drill large holes in the side covers that line up with the coils and install some type of blower motor that will force air across the coils to keep them as cool as possible. Has anyone here rewired one of the crystallite hub motors? IF so, what wire did you use to do this? Any recommendations or things to watch out for? I have searched for links for someone that has done this on here but could not find much. Placed a couple pictures below to show you what happens when you continously place 1500 to 2000W into a motor of this size for an hour at a time.You can even see how burnt the normally white fiberglass insulation had gotten, it is now black
Any ideas or recommendations other than, "less power" would be greatly appreciated.
Thanks again,
Ed
If you don't want to read my history, then just read the last paragraph to see what I am contemplating doing.
First History:
I have not been on the forum for a bit. I finally had put my bike back in operation towards the end of April after multiple issues including a blown controller. Was able to get another 600 miles on it, by the middle of June until driving home late one night I hit the brakes while coming to a stop light and I heard and felt the same noise and vibration I had when the controller blew. I immediately unplugged the controller from the motor but found this did not make a difference, the motor would not roll easily, had the feeling of a stationary bike on the hardest setting. This was about 16 miles into my 20 mile ride home from work at around 11:30 PM and made an already long day much longer. I parked the bike and did not look at it until last week due to other priorities and just overall tired of working on the bike and money put into it.
I have now had enough time to cool off and am looking at my options for getting this going again, but stronger than it was before. I had purchased from Lyen what he had called a Crystalyte 5303 v2 /Phoenix Racer II motor. At the time he said it was the equivalent of an H3540 Motor. This is a rear sensored motor that could go about 36 MPH at 48V. I have a headway headquarters pack that I had put together that was a 2P16S setup 48V Nominal 30 Ah capacity. This was able to get me the 20 miles to work, charge it at work and then back in the evening, averaging high 20 MPH. I would have an elevation change of almost 1000 ft with a 3% grade maximum, but this would get the motor fairly warm by the time I made it to work. I ended up changing my block time from .2 to 2 sec in the controller settings when I got it working again in April since it would give me additional hill climbing power that really seemed to make a big difference in the overall bike operation. I know what many of you will say, "you put too much power into the motor" I agree and take full blame for that, but now I want to get it operational again and would like to have it handle these wattages 1800 to 2200W for the hour long ride into and back from work reliably.
Possible Repair Plans:
I looked into replacement motors from HPC and they recommended a H4080 or H4065 motor with the side cover drilled open, but were talking over $600.00. I contacted Lyen regarding this to see what he would recommend, and I never heard back from him, probably because he is tired of dealing with me.
I am now debating about trying to rewire the motor I have myself using an upgraded magnet wire from a company called Superior Essex. They have a product called Alex that can reliably run up to 240 deg C. http://www.eis-inc.com/Files/pdf/su...loads/superioressex/Allex_240_Magnet_Wire.pdf I would imagine this is much better than the wire that comes in the stock Crystalyte motors. I think the wire gauge that is currently in the motor is either 23 or 24 AWG, but I am not sure about this, need to more carefully measure the wire that is currently in the motor. So my possible plan would be to rewire with the higher temp magnet wire, drill large holes in the side covers that line up with the coils and install some type of blower motor that will force air across the coils to keep them as cool as possible. Has anyone here rewired one of the crystallite hub motors? IF so, what wire did you use to do this? Any recommendations or things to watch out for? I have searched for links for someone that has done this on here but could not find much. Placed a couple pictures below to show you what happens when you continously place 1500 to 2000W into a motor of this size for an hour at a time.You can even see how burnt the normally white fiberglass insulation had gotten, it is now black
Any ideas or recommendations other than, "less power" would be greatly appreciated.
Thanks again,
Ed