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Thread: Wire Sizing for Motorcycle Conversion

              
   
   
  1. #1
    Junior Member
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    Wire Sizing for Motorcycle Conversion

    I am having some trouble with wire sizing of each component in my system. Some of the following is what I have:
    Curtis PMC 1231C Controller
    K91-4003 Motor: K91-4003 Motor
    LiFePo4 Battery pack of 32S 15P (102.4V Nominal and 116.8V Peak Charged)
    ZEVA BMS setup with 3 12 slot modules
    Thunderstruck DC to DC Converter in replace of the Aux battery for my 12V units. TSM 96V DC-DC TSM48DC-DC

    I have the generic wiring diagram from Curtis that I would like to follow:
    Wiring Diagram Curtis 1231C-86XX.JPG
    http://www.thunderstruck-ev.com/Manuals/1231.pdf

    My question is, what wire sizing should I use where? The unit I have is limited to 500 amps Max as per page C-2 in appendix C (Very last page of the manual provided).
    I am starting the build and ramping up my fabrication here in the next few months and would like to to have this topic covered.

  2. #2
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    Hi,
    eventhough in german there is an online calculator about 1/3 down that page:
    https://campofant.com/kabelquerschni...itt-berechnen/
    Just hack in your numbers and hit calculate.
    That will show your losses and from there its up to you to decide.
    Most folks use 35mm2 i think and thats what i use.
    Enough for 200 amps cont. you do not have to sice for max amps battery side.
    Motor side you could bump up to 50mm2-
    Just my 2 ct.
    Flo

  3. #3
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    Quote Originally Posted by flo View Post
    Hi,
    eventhough in german there is an online calculator about 1/3 down that page:
    https://campofant.com/kabelquerschni...itt-berechnen/
    Just hack in your numbers and hit calculate.
    That will show your losses and from there its up to you to decide.
    Most folks use 35mm2 i think and thats what i use.
    Enough for 200 amps cont. you do not have to sice for max amps battery side.
    Motor side you could bump up to 50mm2-
    Just my 2 ct.
    Flo
    I appreciate the comment. I will check out the website to see if it's something I can use.

    I've heard of people using the 35mm2 and the 50mm2 type wires for around the motor, but wanted to be a bit more specific not only with the motor wires, but everything else as well.

  4. #4
    Old EV Racer EVcycle's Avatar
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    PM sent.

    Ed
    EV Ed
    Never let being a responsible adult get in the way of passion and curiosity.
    Motenergy.com
    Ev album 2456, 2458, 2457, 2681, 3456, 3630, 5511, 5512

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