Wiring up the Fisher and Paykel Motor

Installing the 3 phase Cabling
Once you have soldered all the 4,5,6's together, get yourheavy guage of cable, run the cable around the inside of the plastice lip and mark out where all the ones will be soldered to the cable.(in this case car audio power supply cable, available at any car auto store or electronics store) and run the knife around to make a ring, then repeat 10mm down to make a notch. Then run the knife down the length of the cable between the rings you have just cut. i bought a new knife blade to do this with, makes cutting the plastic around the copper a lot easier.

SmartDriveStarConfigurationWiringDiagram

 


Bend the cable until it fits nicely inside the plastic and solder the number 1's to the notches that you made with the knife.

SmartDriveStarConfigurationWiringDiagram

Repeat for number 2's, i used cable ties to hold the second run in place, rather than trying to hold it at the same time as soldering. i used cable ties because it makes it a lot easier to keep the cable in place, but also the cable will get hot when soldering making it hard to hold.

SmartDriveStarConfigurationWiringDiagram

and the same again for number 3's, make sure that non of the copper wires are touching where they shouldnt be.

SmartDriveStarConfigurationWiringDiagram


Eventually you will end up with something that looks like this (ignore the badly soldered ends, i have re soldered the ends and tidied them up to make a far better terminal point). Eventually i will either spray with with some clear coat or make a cover for it to protect it from rain and dirt. Soldering the ends was very difficult do to the size of the cable i have used, i ended up having to use 2 soldering irons at the same time to get the heat i needed.

SmartDriveStarConfigurationWiringDiagram

i will soon post more photos and instructions on how to complete the connection between what you see above and usable terminals that you can bold onto your rectifier.

SmartDriveStarConfigurationWiringDiagram

I will be doing more on this smart drive generator soon, such as mounting, attaching blades and the battery set up.