I melted the motor before the ac wires. I have the pics to prove it too.
My wife towed a ton of shopping home one week and the wires were cool as, and the motor needed hosing down it was soooo hot..
That is interesting! I remember my old 1kw kit phase wires got fairly warm but not hot after a few miles full throttle. Motor got warm too.
Do you have 110 v AC there or 220? That might make a difference?
We have 220 AC.
Was the 1kw kit using 220v rated wires or 120v wires. Its not the same as VXR=I. Voltage rating in wire is calculated by the thickness of each fibre and materials used and current is calculated on how many wires that make the gauge in the cable. Voltage resistance only comes into the math of watts when you consider the length of the wires.
12awg copper wire has a resistance of 0.0055 per meter. Lets run that by ohms law.
V/R=I
50v/0055=9090 amps over a meter of 12awg. Well it aint resistance that is stopping the current.
Now lets do some math on the watts that will create over the wire.
I
2XR=Watts
9090
2X.0055= 454454.55 watts, wow that burning up.
Ohms law doesnt work for awg does it? >>> ¿
Now lets try 20 amps pure DC which is close enough to 12awg current capability.
20
2x.005= 2.2 watts over a 1 meter cable. ahhh thats more like it.
Maybe your motor was passing heat up the wires. High voltage over small fibre wire doesnt melt the wires it causes atrophy and the voltage cant go deep enough into the small fibre so it can create arcs along the current pathways. Lack of resistance does not create large voltage drops over the length so watts are not created.
Use a good thick fibre wire for voltage with many wires for current pathway.
I tried some 50v 50 amp DC rated cable for my battery power cable, it was huge, I think 4awg, but the filament was very fine with lots and lots of filaments. No heat at all, just after long use the filament became brittle all along the cable and breaking up inside the insulator and you could see the copper going green, impurities were being arced into the core of the copper wire. If I continued to use this cable the resistance would of became too much and heat would of became the next issue.
It wasnt the motor use aging the wire so soon when riding, it was the damed 60v 3 amp charger. Wow 3 amps wrecking my 4awg wires . NOT! it was the 60v.
To give you an idea of what is happening here I thought of a good model.
Try to fill up a box with big balls through funnel into a pipe facing downward. Weigh how much is able traveling through per second. Then make the balls tiny and allow them to travel through the pipe at the same speed. Which is going to transfer more weight per second? The tiny balls or the large ones.
Current actually requires surface area, well kind of. The more surface area of a conductor the more current is allowed. SO by increasing the amount of filaments in a cable you increase the suface area for current. Thats the best I can explain it. I'm getting tired.
Voltage issues.
Now think of skimming a stone over a lake. If you throw the stone slow it sinks to the bottom without bouncing off the surface. Throw it fast and it bounce many times off the surface disturbing the surface tension all along its path.
So to voltage bounces along the wire. If the voltage is too high, for the want of a better metaphor, it bounces higher and tries to land deeper into the filaments damaging the surface tension of the wire all along.
But with voltage if you can allow it enough width of bonded conductive ionic molecules, it can get its zap into the filament and wont arc.
Above is some high voltage transmission wire, look at the filament core and how thick each one is.
LeZ
