komodo KH-278 User manual

Komodo Hobby
Building Instruction
&
Manual
KH -278 Outrunner Motor Standard Kit
&
KH -278 Outrunner Motor Advance Kit

Komodo Hobby
www.komodohobby.com
1
Introduction
Congratulations on your purchase of KH-278 Outrunner Motor Standard Kit or KH-
278 Outrunner Advance Kit. This outrunner motor kit includes all parts that you need
to build a powerful motor for your RC plane. In this kit, most of main parts, bell, shaft
holder, main shaft and sleeve, are manufactured by high-end CNC machine. We
would say that it is a state of art outrunner motor kit that hard to find in RC world
today.
Warning
Radio Control Model and Outrunner Motor Kit are not toy!!! It contains sophisticated
small parts and is designed for hobby use only. All parts of this outrunner motor kit
have to be assembled and operated with great care. Outrunner motor can produce
very high power to turn gear or spindle propeller. It is capable of causing property
damage and all bodily harm to operator or spectators. If you are a beginner of motor
builder, please seek assemble and operational help from experienced motor builder.
Be caution!!!
If this outrunner motor kit is not assembled and operated properly, it can destroy your
electronic speed control, receiver, batteries and relevant equipment completely.
Parts List
(QTY) Items
(1) Bell
(1) 23.8mm Stator
(1) Shaft Holder
(1) 3mm Threaded Steel Shaft
(15) NdFeB Magnets
(1) AWG 24, 30ft. Enameled Magnet Wire
(1) 1.9mm C-Clip
(7) Yellow, Red, Blue and Black Shrinking Tubes
(3) M3 Washers
Additional Parts include in Standard Kit:-
(2) KH-278 Copper Sleeves
Additional Parts include in Advance Kit:-
(2) Ball Bearings 3 x 6mm
(3) 2.4mm Connectors (Male)
(3) 2.4mm Connectors (Female)

Komodo Hobby
www.komodohobby.com
2
1. Marks “X” onto magnets
First, place all magnets together as a stack. Use marker to mark “X” on the top of
magnet until all 15 magnets are marked. This step can make sure all magnets will
be placed in NSNSNSNSNSNS magnetic pattern in step 2.
Remark: 3 extra magnets are for your spare parts only in case your magnet is
broken by accident!!!
2. Place magnets inside the bell
Place 12pcs magnets inside the motor bell as the magnetic pattern shown below.
Use a small clip to adjust the distance between magnets and magnets. They
should be placed at same distance and at the edge of bell. Then, use a drop of CA
to secure the position of magnets.
Magnets should be placed at
same distance and at the edge
of bell.
X
X
X
X
X
X
Bell inside
360o

Komodo Hobby
www.komodohobby.com
3
3. Insert main shaft to the center hold of bell
Drop a thick CA glue to the position of main shaft as it shown below. Then insert
the whole front part of main shaft through the Bell carefully.
4. Winding
It is an example of using three individual magnet wires to complete a 3-phases
system. We recommend beginners to wind 12turns for their first motor. For
experienced motor builder, they can wind more or less turns to get different
potential power. Note: Since the last turn is not a complete circle, you need to
wind 13 times to get 12turns’ power. Make sure that every coil has the same
number of windings.
Diagram of winding system of 9-pole stator
65
E1
E2
E3
S3
S1 S2
7
8
9
12
3
4
Magnets
Front Part of Main Shaft
Bell
A drop of thick CA

Komodo Hobby
www.komodohobby.com
4
Phase 1
Step (1): Remain 7-8cm long magnet wire for connection use afterward.
Use magnet wire “S1” to start to wind 13 times in clockwise direction at
tooth No.1. Wind from the hub to the outer edge of hammerhead then
back to the hub.
Step (2): Jump to tooth No. 4 and start to wind 13 times in clockwise direction as
step (1).
Step (3): Jump to tooth No. 7 and start to wind 13 times in clockwise direction as
step (2).
Step (4): Cut the magnet wire “S1”. This ending of wire will be called “E1” in the
following steps. Note: Remain 7-8cm long magnet wire for connection
use.
Phase 2
Step (5): Remain 7-8cm long magnet wire for connection use afterward.
Use magnet wire “S2” to start to wind 13 times in clockwise direction at
tooth No. 2. Wind from the hub to the outer edge of hammerhead then
back to the hub.
Step (6): Jump to tooth No. 5 and start to wind 13 times in clockwise direction as
step (5).
Step (7): Jump to tooth No. 8 and start to wind 13 times in clockwise direction as
step (6).
Step (8): Cut the magnet wire “S2”. This ending of wire will be called “E2” in the
following steps. Note: Remain 7-8cm long magnet wire for connection
use.

Komodo Hobby
www.komodohobby.com
5
Phase 3
Step (9): Remain 7-8cm long magnet wire for connection use afterward.
Use magnet wire “S3” to start to wind 13 times in clockwise direction at
tooth No. 3. Wind from the hub to the outer edge of hammerhead then
back to the hub.
Step (10): Jump to tooth No. 6 and start to winds 13 times in clockwise direction
as step (9).
Step (11): Jump to tooth No. 9 and start to wind 13 times in clockwise direction as
step (10).
Step (12): Cut the magnet wire “S3”. This ending of wire will be called “E3” in the
following steps. Note: Remain 7-8cm long magnet wire for connection
use.
5. Remove the coating of magnet wires
When you finish the winding steps above, you have 6 endings of magnet wire
attached to coils. Use a shape model knife to scrape off the coating of these six
magnet wires.
Finally, it is necessary to check any short between magnet wire and stator metal
parts, and need to check any short between magnet wires, S1, S2 and S3. If you
find any short between them, please be patience to rewind them again. Please
note that your Electronic Speed Controller, Receiver and Battery can be destroyed
by part defect of windings.
6. Solder magnet wires to Delta or Wye system
Now, you can make you own decision to solder the magnet wires to either Star
(wye) or Delta system.
Star vs Delta
9Star (wye) system gives more torque and uses fewer amps.
In Star system, 1.73 less turns needs to be wound to get the same power and
Kv as DELTA system does.
9Delta system gives 1.73 higher power and amps draw compare to STAR
system.
In Delta system, the Kv is 1.73 higher than Star system while the Kt (Torque)
is 1.73 lower

Komodo Hobby
www.komodohobby.com
6
Star (wye) system
6 5
Solder E1, E2 & E3
Together
S3
S1 S2
7
8
9
12
3
4
6 5
Delta System
Solder
E3 to S1
7
8
9
12
3
4
Solder
E1 to S2 Solder E2 to S3

Komodo Hobby
www.komodohobby.com
7
7. Insert three soldered wires to Shrinking Tubes
Finally, you get three soldered wires attached to coils. Insert those soldered wires
into shrinking tubes for insulating.
9. Inserts Shaft Holder to Stator as it shown below
10.A drop of Loctite to copper sleeves or ball bearings and insert them into
shaft holder.
Note: Make sure lubricant is added to inside of copper sleeves before run the motor.
11.Slot Main Shaft Holder to the Main Shaft
Stator
Shaft Holde
r
Magnet wires
A drop of Loctite
Shaft Holder
Bearing
Magnet Wires
Bearing

Komodo Hobby
www.komodohobby.com
8
12.Put M3 Washer and Slot a C-clip to the end of main shaft to secure whole
motor system.
Congratulation!
You finished the assemble work of your unique outrunner motor. You can install this
outrunner motor to Shock Flyers, Park Flyers or RC Indoor Planes. We would like to
thank you for your purchase. For more other selections of outrunner motor kit, please
visit the site at www.komodohobby.com
Should you have any comments of this outrunner motor kit, please feel free to contact
us at [email protected]
C-clip
M3 Washe
r