Motor Connectors and Wires

[Cyclezee]

An example of differences between wiring and connectors can make a big difference to the performance and reliability of electric bikes, these details are not noticeable without close examination.

Below is a comparison of motor wires and connectors used by eZee and generic Chinese brands.

The eZee pin diameter is 4.5 mm, a typical generic Chinese connector is 1.5 mm.

The eZee copper power wires are 2.5 diameter ~ SWG 12 and have a continuous power rating of 7.4 amps, typical generic Chinese power wires are 1.5 mm diameter ~ SWG 17 and have a continuous power rating of 3.7 amps.

Of course the eZee wiring costs more, but they believe function is more important than form.


The photo below illustrates the differences, The eZee connector is on the left, generic Chinese on the right

 

[shemozzle999]

I think you mean the power connector pin diameter not the wire diameter.

Brushless motors only work at 1/3 duty cycle so the continuous power rating is only stated for worst case conditions i.e. at the highest operating temperature with natural air cooling of the cable.

Thermal runaway of the cable could occur if these parameters are exceeded, but as we use them on a moving bike we have the advantage of forced ventilation around the cable.

Both should be capable of delivering the required power to legally rated motors as long as there are no weak links in the end to end wiring including the solder joints on the motor and controller.

I like the new era cabling as you can quickly unplug the motor and remove the wheel for tyre/tube repairs, are able to remove all the nuts and washers off the motor without unleashing the cable from the bike frame (due to the small connector diameter) and finally, with the addition of a light application of vaseline to the inside of connector achieve a sound weatherpoof seal.

Did I mention I have a few of these for sale in the classified section
Seach for Replacement motor cables.

 

[amigafan2003]

The eZee copper power wires are 2.5 diameter ~ SWG 12 and have a continuous power rating of 7.4 amps

@ what voltage?

 

[flecc]

I think you mean the power connector pin diameter not the wire diameter.

They did specify both pins and wires separately with respective diameters:

The eZee pin diameter is 4.5 mm, a typical generic Chinese connector is 1.5 mm.

The eZee copper power wires are 2.5 diameter - - - - - typical generic Chinese power wires are 1.5 mm diameter

 

[shemozzle999]

I think he is talking about the overall diameter of the cable including sheathing not the copper content.
It is more common to describe wires by the number of strands and the diameter of each strand so a better comparsion can be made.

 

[flecc]

Thanks shemozzle, understood. Hopefully and likely to have thicker cores though, more important with their high power motor setup.

 

[shemozzle999]

For the record, the Chinese generic sample cables I purchased from Outrider are as follows:

3 Pin - Non-Hall Cable

3 x 19/0.32mm dia. equivalent 1.53mm sq cross sectional area, ptfe sleeved, overall cable 5mm diameter,
rated 20A.
Male length - 300mm / Female length 1800mm.

9 Pin - Hall Cable

3 x 19/0.25mm dia. equivalent 1.0mm sq cross sectional area, ptfe sleeved, overall cable 6mm dia. -rated 15A.

plus

6 x 7/0.2mm dia. equivalent 0.35mm sq cross sectional area, ptfe sleeved.
rated 3A.

Male length - 300mm / Female length 1800mm.

I can also cut either of the the female connector cables to match existing cable length and teminate to a new standard 6 way controller connector and/or the 3 male crimp bullets.