Phase bullet insulation fused

[Marctwo]

I've been getting power fluctuations over the last few days so I decided to check out the phase connectors.

The insulation on the 3 bullet connectors was blackened and welded to each other. On pulling them apart some bare connector was showing. The male/female sides were also completely welded together.

After cutting off the insulation, I found the connections to be quite loose which would account for at least some of the excessive heat. I never liked these bullet connectors anyway.

I've now tightened the connections a bit and put some tape around them. The power seems stable but I'm thinking of changing the bullets for one of the 3 blade power connectors found on controllers.

Any thoughts?

 

[Deleted member 4366]

If you have a connector near the motor as well, you don't need a connector at the controller, so you should solder these connections together, or better still, solder them directly to the controller pcb.

 

[Scimitar]

I've found these bullet connectors to be particularly horrible and fitting only where they belong - on a 1950s Morose Minor.
Much better to replace with something more modern and reliable.

 

[103Alex1]

Yep I hated those things - looked like a recipe for problems. Solder together / onto PCB.. or if you want to be able to take out the controller without having to cut off your cable ties and remove a load of cable with it use something better.

I fitted Anderson Powerpole connectors instead and they're much better once you get the pins in (multimeter probe is particularly good for this). As there are 3 phase wires you can put together a block which can't be fitted the wrong way round using 2 reds and a black or 2 blacks and a red. It's a bit like playing with lego .

 

[Geo13647]

Yep I hated those things - looked like a recipe for problems. Solder together / onto PCB.. or if you want to be able to take out the controller without having to cut off your cable ties and remove a load of cable with it use something better.

I fitted Anderson Powerpole connectors instead and they're much better once you get the pins in (multimeter probe is particularly good for this). As there are 3 phase wires you can put together a block which can't be fitted the wrong way round using 2 reds and a black or 2 blacks and a red. It's a bit like playing with lego .

I use this for powerpoles.
http://http://www.ebay.co.uk/itm/INSERTION-EXTRACTION-TOOL-30AMP-45AMP-ANDERSON-POWERPOLE-CONTACTS-/230956476196
Works well for me.

Geo...

 

[103Alex1]

I use this for powerpoles.
http://http://www.ebay.co.uk/itm/INSERTION-EXTRACTION-TOOL-30AMP-45AMP-ANDERSON-POWERPOLE-CONTACTS-/230956476196
Works well for me.

Geo...

^^ That's the proper way ... I was too tight to buy one for the sake of 12 'insertions'. The "genuine" connectors aren't especially cheap in small quantities it has to be said, but it's so fundamental to the bike working probably money well spent to be honest.

 

[Marctwo]

Cheers guys,

I may get some of those powerpoles to have a look at them in the flesh.