improving MXUS 3000 V2

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unclejam   10 W

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Re: improving MXUS 3000 V2

Post by unclejam » Apr 20 2015 3:48pm

More indoor unloaded testing tonight, first wot run got just 27.5 mph with 76volts in the pack, phase wires steaming hot after just 20 seconds. Second run didn't happen as motor dead and CA showing no current draw.
Rear wheel "cogs" when turned by hand but spins freely when phases are disconnected.

From my previous studies, I now believe the phase wires have melted and shorted. Excellent.
This can't be right after just two short runs surely??

Before anyone asks, no there are no problems with the wheel spinning freely, or anything rubbing!
Somebody shoot me.... :cry:
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Allex   1 GW

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Re: improving MXUS 3000 V2

Post by Allex » Apr 20 2015 4:20pm

Could probably be a few FETs blown in the controller due to wrong combination of phase/hall wires. It sucks, but at least lesson learned, if your phase wires/controller are getting hot to the touch by just doing some full throttle runs with the wheel up in the air - bad wire combination.

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unclejam   10 W

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Re: improving MXUS 3000 V2

Post by unclejam » Apr 20 2015 5:59pm

Is the lesson learned " don't use the wiring combination that the motor supplier gives you" ???? :shock:
So it's time to send the controller back to Lyen in San Francisco?
This is turning out to be a bad week......
“Begin doing what you want to do now. We are not living in eternity. We have only this moment, sparkling like a star in our hand and melting like a snowflake...” Francis Bacon

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Allex   1 GW

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Re: improving MXUS 3000 V2

Post by Allex » Apr 20 2015 6:26pm

Something like that :(
On top of that, you probably need to change your phase wires AND hall wires, if you had a "meltdown" chances are big that some of the hall wires could be shorted as well.
Motor supplier does not know what controller combo is working 100% on different controller. But if they deliver both motor and controller then they should of course provide the right combination.

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teklektik   10 GW

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Re: improving MXUS 3000 V2

Post by teklektik » Apr 20 2015 7:01pm

unclejam wrote:From my previous studies, I now believe the phase wires have melted and shorted.
Allex wrote:Could probably be a few FETs blown in the controller due to wrong combination of phase/hall wires.
Ya - sounds like controller, not phase wires.

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Relanium   10 W

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Re: improving MXUS 3000 V2

Post by Relanium » Apr 21 2015 12:07am

Here's my phase wire upgrade in progress on the V1. Using same cables as @madin88.
And that axle entrance outside realy is sharp, can easily peel cables.

Image

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Relanium   10 W

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Re: improving MXUS 3000 V2

Post by Relanium » Apr 21 2015 12:10am

madin88, what stuff do you use to glue cables back together to the axle?

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madin88   100 MW

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Re: improving MXUS 3000 V2

Post by madin88 » Apr 21 2015 3:41am

i have used standard black silicone, but in future i will use sikaflex (552 type) because it sticks much better than silicone. i have already worked with it and its aweseom how strong it holds.
yes the edges where the wires enters the axle are extremely sharp. you should grind them to a nice round shape.
it looks like you have not been able to put the bunch of wires together with shrinktube covered through the axle. it was not easy, but when i placed in every gap 2 hall wires (like its done in stock wire) and cover them with thin tesa film before adding shrinktube (so they stay at its place), it should be doable :)
- 10kW belt drive with Neumotor 8057: viewtopic.php?f=30&t=91144&start=50#p1377787
- Fully road legal (L1E approval) e-bike based on Votec V-FR frame
/ MXUS 3T / 17" Mitas MC11 / Adaptto Max-E / 20s12p 25R
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Allex   1 GW

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Re: improving MXUS 3000 V2

Post by Allex » Apr 21 2015 4:09am

Madin, I am thinking of buying those cables you linked to, so they go in without problems along with the hall wires inside the stock axle?

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madin88   100 MW

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Re: improving MXUS 3000 V2

Post by madin88 » Apr 21 2015 4:30am

Allex wrote:Madin, I am thinking of buying those cables you linked to, so they go in without problems along with the hall wires inside the stock axle?
yes they definitely will fit together with the stock hall wires. if you want to cover all wires with shrink tube it needs more care but its possible (if you do like described in above post).
- 10kW belt drive with Neumotor 8057: viewtopic.php?f=30&t=91144&start=50#p1377787
- Fully road legal (L1E approval) e-bike based on Votec V-FR frame
/ MXUS 3T / 17" Mitas MC11 / Adaptto Max-E / 20s12p 25R
- KTM Hardtail Pedelec / eZee V2 6T / 27,5" / Kelly KBSX @ 1,5kW / Torque PAS / CA-V3 / 13s4p Sanyo GA in Shark case

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madin88   100 MW

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Re: improving MXUS 3000 V2

Post by madin88 » Apr 21 2015 4:31am

thats the axle i'm going to offer soon for sale:
http://endless-sphere.com/forums/viewto ... 5#p1037124
- 10kW belt drive with Neumotor 8057: viewtopic.php?f=30&t=91144&start=50#p1377787
- Fully road legal (L1E approval) e-bike based on Votec V-FR frame
/ MXUS 3T / 17" Mitas MC11 / Adaptto Max-E / 20s12p 25R
- KTM Hardtail Pedelec / eZee V2 6T / 27,5" / Kelly KBSX @ 1,5kW / Torque PAS / CA-V3 / 13s4p Sanyo GA in Shark case

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Relanium   10 W

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Re: improving MXUS 3000 V2

Post by Relanium » Apr 21 2015 6:14am

madin88 wrote:
Allex wrote:Madin, I am thinking of buying those cables you linked to, so they go in without problems along with the hall wires inside the stock axle?
yes they definitely will fit together with the stock hall wires. if you want to cover all wires with shrink tube it needs more care but its possible (if you do like described in above post).
Yep, still some space without shrink tube. With shrink tube there's the problem with bulging.
Will put shrink tube on from outside into the axle as far as possible, and hope it's enough :)

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unclejam   10 W

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Re: improving MXUS 3000 V2

Post by unclejam » Apr 21 2015 3:19pm

teklektik wrote:
unclejam wrote:From my previous studies, I now believe the phase wires have melted and shorted.
Allex wrote:Could probably be a few FETs blown in the controller due to wrong combination of phase/hall wires.
Ya - sounds like controller, not phase wires.

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Many thanks for the advice everyone. Looks like it's time to find a new controller, repair is probably not financially sensible :(
Anyone got a spare 100v 60A controller they want to sell??
“Begin doing what you want to do now. We are not living in eternity. We have only this moment, sparkling like a star in our hand and melting like a snowflake...” Francis Bacon

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striker54   100 W

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Re: improving MXUS 3000 V2

Post by striker54 » Apr 21 2015 4:11pm

unclejam wrote:Anyone got a spare 100v 60A controller they want to sell??
Not 60A but if you want it: http://endless-sphere.com/forums/viewto ... 2#p1035304

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unclejam   10 W

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Re: improving MXUS 3000 V2

Post by unclejam » Apr 21 2015 5:14pm

Thanks for the offer but I'm running at 80v, so this wouldn't be beefy enough.
“Begin doing what you want to do now. We are not living in eternity. We have only this moment, sparkling like a star in our hand and melting like a snowflake...” Francis Bacon

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unclejam   10 W

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Re: improving MXUS 3000 V2

Post by unclejam » May 06 2015 6:32am

Hi guys. Got a replacement controller but now got another problem :(
I noticed that several of the brake rotor bolts on the MXUS motor have become loose and on investigating / tightening again, they are stripped!
I haven't over-torqued them and am now wondering if anyone else has experienced this issue and if so, how did you solve it?
(Luckily i have a tap and die set if necessary...)
Thanks for any help - yet again!!
“Begin doing what you want to do now. We are not living in eternity. We have only this moment, sparkling like a star in our hand and melting like a snowflake...” Francis Bacon

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unclejam   10 W

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Re: improving MXUS 3000 V2

Post by unclejam » May 06 2015 6:45am

I'm told - "Longer bolts !!!!"
Sounds good to me :lol:
“Begin doing what you want to do now. We are not living in eternity. We have only this moment, sparkling like a star in our hand and melting like a snowflake...” Francis Bacon

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Cowardlyduck   10 MW

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Re: improving MXUS 3000 V2

Post by Cowardlyduck » May 06 2015 7:01am

Same thing happened to one of my previous Crystalyte HS40xx motors. I got longer bolts and got them in titanium and it fixed the issue on all but one hole. For that hole I just put heaps of locktight in there and it was all good. :)

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unclejam   10 W

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Re: improving MXUS 3000 V2

Post by unclejam » May 06 2015 9:51am

Cheers for the advice Mr Duck!
Apparently its happened before to users of this motor. I'll wind some longer ones in there. :wink:
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Re: improving MXUS 3000 V2

Post by 9lives » May 07 2015 5:08am

The disk bolts are on the short side and I had mine come lose as well despite lock tight (running a spacer to be fair). A couple holes were likewise stripped but the bolt holes have some depth so I went with longer bolts to match and nil issues since then.

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unclejam   10 W

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Re: improving MXUS 3000 V2

Post by unclejam » May 07 2015 5:57am

Yeah, I have used a new set of longer bolts with thread lock and they have all tightened up fine.
Job done. (Wheelies away into the sunset!) :twisted:
“Begin doing what you want to do now. We are not living in eternity. We have only this moment, sparkling like a star in our hand and melting like a snowflake...” Francis Bacon

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Allex   1 GW

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Re: improving MXUS 3000 V2

Post by Allex » May 15 2015 7:34pm

Well and I am doing the upgrade by my proved Method - Turnigy wires with removed silicone insulation and covered with shrink tube instead.
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Oh and the C-ring was not snapped in its place! Not liking it. This would mean that we need to open up every motor and check if everything is ok in there.
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Cowardlyduck   10 MW

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Re: improving MXUS 3000 V2

Post by Cowardlyduck » May 15 2015 9:39pm

Allex wrote:Well and I am doing the upgrade by my proved Method - Turnigy wires with removed silicone insulation and covered with shrink tube instead.
This is such a good method. It should become the standard for all those doing phase wire mods. :)

Why are you going 12AWG though? I would have thought the MXUS axle slot was big enough for 10AWG.

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Re: improving MXUS 3000 V2

Post by BoomerChomsi » May 16 2015 6:58am

Thanks for your sharing, I like it! 8)
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Allex   1 GW

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Re: improving MXUS 3000 V2

Post by Allex » May 16 2015 8:08am

I believe that 12AWG is sufficient for this motor at least for this particular one. Dont think 10AWG would fit in there.

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