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Unread 01-09-2009, 10:51 AM   #11
nimda
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Default Re: Melting wires????

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Originally Posted by A.D. View Post
I upgraded the wire to 10awg on all the wire except the wires going from the V-Glide to the coils because i could not get a connector small enough to fit the V-glide side. It is melting at the ends not in the middle

Thanks for all the help
Do what? You can't run 10awg wire on there dude. You need at least 6 gauge cable. You'll keep burning them up. dereckbc was right, too much load on that wire. They will never hold up. And you say you "upgraded"...what was on there before 24 guage?
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Unread 01-09-2009, 10:58 AM   #12
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Default Re: Melting wires????

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Originally Posted by A.D. View Post
I upgraded the wire to 10awg
Just caught that part. A fire is in your future.
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Unread 01-09-2009, 12:16 PM   #13
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Default Re: Melting wires????

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Originally Posted by roady89 View Post
Do what? You can't run 10awg wire on there dude. You need at least 6 gauge cable. You'll keep burning them up. dereckbc was right, too much load on that wire. They will never hold up. And you say you "upgraded"...what was on there before 24 guage?
Now we're getting somewhere, OP might be thinking the higher the number (gage #) the bigger the wire.

I think we have the oposite of the old saying "hotdog down a hallway"!

Would love to know what was on there before, gotta go with AT LEAST a 6 ga, high strand count cable and good crimped or better, soldered ends.

Bet that thing glows like a light bulb element at night......
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Unread 01-09-2009, 01:06 PM   #14
nimda
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Default Re: Melting wires????

FYI, Don't buy wally world cables. They are not much better than what you have.
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Unread 01-09-2009, 01:42 PM   #15
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Default Re: Melting wires????

I will have to double check the AWG,but they are twice as big as what came on it, but it was a 36v cart prior to the upgrade. Thanks for all the help.
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Unread 01-09-2009, 02:13 PM   #16
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Default Re: Melting wires????

AD we are not trying to scare you. Take that back, yes I am.

What you are saying concerns some of us. # 10 AWG is totally inadequate and is a real fire danger. # 6AWG is border line safe, #4 AWG is OK, # 2 AWG is Good, and 1/0 and larger is EXCELLENT. The real problem is most folks and DIYer's do not have the tools or compression terminals to terminate the cable with because they are very specialized and expensive.

Even the insulation type is very important, most are unaware of what insulation type means or the application, but it has to do with HEAT and operatiing tempurture.
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Unread 01-09-2009, 02:19 PM   #17
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Default Re: Melting wires????

i checked and they are 4awg wires
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Unread 01-09-2009, 02:23 PM   #18
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Default Re: Melting wires????

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i checked and they are 4awg wires
OK if the insulation is melting near the terminations tells me either the compression fitting are poorly installed, or the connection to the post is loose. Either way the root cause is high resistance and the current is heating up and melting the insulation.

Not only is this a safety hazard but is also robbing you of performance with undue voltage drop and power loss.
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Unread 01-09-2009, 03:24 PM   #19
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Default Re: Melting wires????

well i just took it apart and noticed that both ends at the a1 and a2 connection are were it is melted the other end of each are justfine???
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Unread 01-09-2009, 03:32 PM   #20
nimda
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Default Re: Melting wires????

So both A1 and A2 cables are melted on the ends, where the cable bolts to the motors A1 and A2 terminals? Either those cables have a bad connection or possibly the feild coil is shorting out. The other end being fine is nothing out of the norm.
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