Wiring up the Fisher and Paykel Motor

For rewiring you will require:
Smart Drive Motor
Heavy Guage Wire, capable of around 25amps (I used Heavy Duty audio power cable, slight overkill)
Soldering Iron + solder
400 Grit Sandpaper
Heat Shrink
Electrical Tape
Cable Ties

There are many options when Re-Wiring the smart drive.
i have chosen the star configuration as it is the most commonly used and also it is the easiest to do.


Understanding Re-wiring the Smart Drive Generator
This part seems tricky but once the wiring is understood it is easy, essentially you splitting the 42 coils into groups of 6 (into a star pattern). When rewiring you are simply repeating the process of soldering the 6 coils together.

Theory of Wiring for Star Pattern on Smart Drive Motor.

This is the Original Wiring of the Smart Drive Motor.

SmartDriveWiringOriginal


This is the Wiring Diagram that you will repeat 7 times around the coil. Orange, Green and Blue bars below represent the three heavy guage copper cables seen on the next page.
SmartDriveStarConfigurationWiringDiagram


Mark out 1,2,3,4,5,6 on the coils around the inside of the plastic, then repeat around the coils until you have 7 groups of 6 coils.

Then you can start to cut the joins between 4 - 1 , 5 - 2 and 6 - 3. note that you must cut between 4 on the first group and 1 on the second group, the same applies for 5 and 2, as well as 6 and 3.
Do not cut between 1 and 4 on the first group, the same for 2 and 5, as well as 3 and 6.

You must leave enough wire on 4,5 and 6 so you are about to connect the ends together and solder.

SmartDriveStarConfigurationWiringDiagram

 


Continue to cut the wire all the way around.

SmartDriveStarConfigurationWiringDiagram

grab 4,5,6

SmartDriveStarConfigurationWiringDiagram

At this point you will want to use some 400 grit sand paper to start sanding off the varnish that is put on there to stop corrosion. I found the best way to do this was to use a pair of needle nose pliers to hold the base of the copper wire and then fold tiny peices of sandpaper about 1 inch in half and squeeze the copper wire inbetween your fingers with the sandpaper. you will know when you have gotten through to the raw copper when you see a small difference in colour, it will be a slightly lighter colour than before. you will want to do this about 10mm down the copper wire on all of the wires.

Twist the ends together as best you can. if you use pliers to twist the ends together, be very careful not to break the wire.

SmartDriveStarConfigurationWiringDiagram


Then solder the ends of 4,5,6 together.

SmartDriveStarConfigurationWiringDiagram