Crystalyte HS3540 Sensorless hub motor - new phase wires

Crystalyte HS3540 Sensorless hub motor - new phase wires

I use this motor with a 7245 sensorless controller, 48V or 72V (2 or 3 batteries), 45A max. or less, set with Crystalyte APM display.

Checking my batteries SOC on the 48V set (58.4V fully charged), I've detected 54v between the frame and the negative of the batteries.
Begin checking the batery serial cable to controller connections. After disconneting the phase wires the problem disappeared, 0v.
It was the second time it occurs. First time, a couple of years ago, I limited myself just to use some heat-shrink to repair. It´s the old problem with HS3540 Cx motors.
It's time to change the phase wires. Beeing sensorless it's a easier task,I think.
Good timing. The wife gone for a week to my daughter's home to take care our ailling grandson. I can make it without interrupts.
I had allready all the wires, XT150 connectors,etc to work.
After opening the motor the first thing I saw was some copper windings touching the stator. To avoid shorts between the the hub and the windings, separated the windings from the stator and applied some silicone between.
Checking the phase wires I saw some insulation cuts on the yellow wire.
It was necessary to change the wires.
The new copper wires are silicone coated and slightly thicker than the old .
My thanks to the inventor of zip ties.
Now seriously:
I want to thanks Endless Sphere forum. Almost all I know about EVs it was learned on that magnificent forum.
Here's some pics.
BIG ODDS
DIY

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