Simple Motors Kit 9 User manual

Assembly instructions for kit #9
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Assembly Instructions: Kit #9
Kit #9 is essentially Kit #8 where with a simple turn of the knob you can switch between four
different motors:
•R – Regular reed switch motor
•T – Reed switch motor with the transistor
•H – Hall Effect motor
•O – Motor with optical control
If you are adding the switch to already assembled Kit #8 please note the revised steps on
attaching the Hall Effect switch and the resistors.
1. Insert the T-pin into one of the caps.

Assembly instructions for kit #9
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2. Insert the rotor core into the same cap as shown below. Apply some pressure to push the
rotor core approximately 1/2" (10-12 mm) into the cap.
3. Put in the wooden insert.
4. Insert the pushpin into the other cap until it is fully seated and the end of the pushpin sticks
out approximately 1/4" (6-7 mm). You may need to push it hard.
5. Put everything together as shown below. Push the caps towards each other until they
cannot move any more. The T-pin must be secured firmly. This process may require some
strength. Be careful not to bend the T-pin or poke yourself.

Assembly instructions for kit #9
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6. Glue the magnets to the flat surfaces of the rotor core with the letter ‘S’ facing outside (or a
dimple facing inside). Your kit includes 4 magnets. If you want to try 2 magnets first, glue
them to the opposite sides. Straighten the T-pin if necessary. You can check it by spinning
the rotor between your thumb and index finger. Again, be very careful.
All kits have magnets with one of the poles marked with either a letter ‘S’ on the South pole
or a dimple on the North pole. If you want South side to look better, you may cut out the
white glossy round labels that are provided and paste them. You may do it before attaching
the magnets to the rotor. It is recommended to use regular white glue or a glue stick on the
labels for better results.
7. Cut out the disk (supplied with the kit). Poke a hole in the center, which is marked by a
cross. Apply some glue to the middle of the disk and glue it to the cap with a shorter axle
(with the pushpin). Slide two sequins as shown below. The sequins act as a spacer between
the disk and the stand and work better if their convex surfaces face outwards. You may use
only one sequin with convex surface facing the stand.
8. Insert the rotor into the stands marked with blue and silver stars as shown below. Hold the
stands and test to see if rotor spins freely. Make final adjustments to the T-pin if necessary.
9. IMPORTANT: If you plan to attach propeller to your motor try to glue the stand with the
blue star as close to the edge as possible. You may need to shift the whole rotor assembly.
Glue the stand with the silver star to the board. Try to cover the corresponding star
completely. Align the marks on the stand with the line on the board as shown below. Note
that the star's position and the marks are approximate, sometimes you need to move the
stands slightly to achieve the lowest friction. Keep in mind that super glue bonds instantly,
so try to be as accurate as possible in these procedures.

Assembly instructions for kit #9
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10.Insert the rotor into the stand marked with the blue star. Glue it to the board the same way
as the first stand. Leave a gap of about 1/16" (1/32", or 0.8 mm on each side) between the
rotor and the stands. Test again to see if the rotor spins freely. At this time, or later, you
may take the rubber plug and fix it as shown below. You can glue different things to the
outer flat surface of the plug. Try to be accurate, redo this step if necessary.
11.If you purchased the wire comparison kit, instead of steps 11-13 for this kit, follow
instructions for wire comparison kit. After that, please, continue the assembly instructions
from step 14.
Otherwise, insert the nail into the stand with the green star. If it is loose you may apply
glue as shown below.

Assembly instructions for kit #9
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12.Cut two pieces of wire 9" (22-23 cm) long. Leave them for now - they will be used for
connecting the reed switch. All remaining wire on the spool should be used to wrap around
the area between the tape and the head of the nail.
oTape one end of wire leaving about 6" (15 cm) open. You may use the tape that is
already on the nail.
oWind all the wire in one rotational direction (either clockwise or counterclockwise)
moving back and forth along the nail. Try to be as accurate as possible. Do not let
the wire slide off the end of the electromagnet.
oTape the second end of the wire using the same tape. Both open ends of wire should
be about 6" (15 cm) long.
oClean about 3/8" (10 mm) of the wire tips with fine sandpaper (included) or a sharp
knife to remove the insulation.
Test the electromagnet! Connect one wire to "+" and another wire to "-" of the battery. If
electromagnet is assembled correctly the head of the nail should attract metal objects such
as paper clips, small nails, knife blade, etc.
13.Glue the electromagnet to the board as shown below. Turn the rotor slowly to see if the
magnets hit the electromagnet. If one or more do, move the electromagnet back until there
is a 1/16" (1.5 mm) gap between the electromagnet and the closest magnet on the rotor.

Assembly instructions for kit #9
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14.Locate the optointerrupter pins as shown on the following picture. It is very important to
identify all four pins properly. Wrong connection in the motor will destroy the
optointerrupter.
Bend and trim optointerrupter pins as shown below (view from non-branded side). Tweezers
or needle-nose pliers may be very helpful. You may use scissors for trimming.
Locate the 270 Ohm and 4.7 K (4700 Ohm) resistors. The 270 Ohm resistor has red, violet,
brown and gold color bands. The 4.7 K resistor has yellow, violet, red and gold color bands.
Bend the leads of the resistors as shown below.
Solder these resistors together and to the optointerrupter as shown in the next picture. See
the Links page at our web site for tips on soldering if you do not have enough experience in
this procedure.
IMPORTANT: Do not overheat the optointerrupter when you solder it. The soldering iron
heat may destroy this sensitive device. If you were unable to attach the wire in 3 seconds,
let the optointerrupter cool off, and then try it again.

Assembly instructions for kit #9
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Make sure that 270 Ohm resistor is connected to LED cathode, 4.7 K resistor is connected to
the emitter of the phototransistor, and LED anode and the collector of the phototransistor
are connected together:
15.Solder 3 pieces of the hook-up wire to the optointerrupter assembly. If your kit includes one
large piece of hook-up wire, cut it into 8 pieces of about 9” (22-23 cm) each; if it includes
four 18” long pieces cut them in half. Strip about 3/8" (10 mm) of insulation on each end of
these wire pieces using a sharp knife.
Wire colors shown on the picture are used for reference only. You may use different colors
or even one color.

Assembly instructions for kit #9
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16.Locate two marked lines and glue the optointerrupter to the square wooden stand as shown
below with branded side facing up (shown without the resistors):
17.Attach the self-sticking felt pad to the reed switch stand as shown. This soft pad decreases
the reed switch vibration thus decreasing the sound it generates.
18.Assemble the reed switch on universal stand. You may add a ZNR if you want to experiment
with higher voltages or make more reliable reed switch motor. The ZNR is a small electronic
part that absorbs the spark inside the reed switch. It provides an additional reed switch
protection even in the motor with the transistor.
The ZNR is not required for the motor to work. You may also add it later.
Take the two pieces of magnet wire you cut earlier and clean the wire tips using sandpaper
to remove the insulation. Clean about 3/8" (10 mm) on both ends of each wire piece.
Form ZNR leads as shown below. Solder wires to the reed switch and the ZNR.
Solder the second wire and insert the reed switch wires into the universal reed switch/Hall
Effect switch stand. Be careful not to break the reed switch, it is very fragile. Twist the
wires. Make sure that the reed switch is not centered on the stand and shifted to the side as
shown in the pictures.

Assembly instructions for kit #9
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Use rubber band to prevent the reed switch from moving. The ZNR should be located below
the reed switch.
19.Bend the leads of the Hall Effect switch apart and solder three wire pieces to them. Do not
overheat the Hall Effect switch.
20.Insert the Hall Effect switch into the universal stand as shown below. Note that reed switch
and Hall Effect switch will be controlled by different magnets to reduce the interference.
Make sure that the leads of the Hall Effect IC do not touch each other and branded side is
facing down.

Assembly instructions for kit #9
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21.Glue the universal stand to the board as shown in the picture below. The Hall Effect switch
and reed switch should be located at the closest distance from the magnets. Check the
rotation of the rotor to make sure that the magnets do not hit any of the switches.

Assembly instructions for kit #9
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22.Glue the optointerrupter stand to the board as shown in the picture. If you rotate the rotor,
the disk blades should be in the middle of the slot as deep as possible without hitting the
optointerrupter. You may apply the glue to the board to prevent it from soaking into the
stand. Hold the middle part of the rotor and rotate the cap that has the disk attached until
one of the blades is inside the slot. You will need to experiment with it later to find the best
position of the disk to provide a good start and the best speed.
23.Attach the battery holder to the board. The battery holder allows you to experiment with 4
different voltage settings (1.5, 3, 4.5, and 6 V DC). You will need 4 AA size batteries.
To understand how the jumper wire works let's take a look at the connections inside a
typical battery holder:

Assembly instructions for kit #9
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The following diagram shows how to get 1.5, 3, 4.5, and 6 Volts using 1, 2, 3, or 4 batteries
and a jumper wire shown in blue color. Arrows show the current flow for 1.5, 3, and 4.5
Volts settings. Could you trace the current when all 4 batteries are inserted (there is no
jumper wire in this case)?
Inspect your battery holder – it may have different connections inside. In this case you can
still use the jumper wire in the same manner to get all 4 voltages, but you will need to find
appropriate connection points for each voltage setting.
Insert bare ends of the jumper wire between the spring and plastic case to make a good
contact and hold them in place. This is how the jumper wire is actually used for 3 Volts
experiments (one end is disconnected and may serve as on/off switch):
Insert the batteries and briefly connect battery holder wires to the electromagnet. If
electromagnet is connected properly it should repel the magnets on the rotor turning it 45°
as shown below. If it does not work – switch the wires.

Assembly instructions for kit #9
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After finding the correct connection mark the positive red wire from the battery holder and the
wire from the electromagnet – they will be connected together.

Assembly instructions for kit #9
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24.Mark the wires from the optointerrupter and a Hall Effect switch. It is recommended to mark
at least the wires that have the same color. You may use the electrical diagram from the
Appendix A to have the same letters – it will simplify their identification later.
25.Arrange and route the wires as shown. You may use a scotch tape to hold them in place.

Assembly instructions for kit #9
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26.The following diagram shows the connection of all the wires to the switch. Note that all the
letters are corresponding to the electrical diagram at the end of these instructions (see
Appendix A).

Assembly instructions for kit #9
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Connect connection points O3-O4, H3-H4, T3-T4, O1-O6, H1-H6, T1-T6, T5-R3 and T3-R1
using pieces of unused wires.
27.Temporarily attach the switch to the bracket and solder all the wires as shown below. Use
the diagram from previous step with the electrical diagram from Appendix A.
IT IS EXTREMELY IMPORTANT TO CHECK AND DOUBLE CHECK ALL YOUR CONNECTIIONS!
If you connect wrong wires the motors will not work and you may even destroy some
electronic parts.

Assembly instructions for kit #9
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28.Locate the base (B), collector (C) and emitter (E) leads on the transistor:
Bend the leads of the transistor as shown:
29.Attach the transistor to the bracket and solder it to the switch (collector is soldered directly
to the switch; base and emitter are using two wire pieces):
Usually the bracket provides enough heat dissipation for voltages up to 12 Volts. If you plan
to experiment with higher voltages you may add a heat sink as shown:

Assembly instructions for kit #9
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30.Tighten the knob on the switch using a set screw on the side and turn it counterclockwise
until the last click, then remove the knob. Now add all the washers and a dial as shown:
Attach the bracket to the board. If you bought Kit #9 your board is predrilled and
countersunk. If you are adding the switch to the Kit #8 you need to drill 2 holes.
Hardware is included with the switch. You may also use strong double sided tape.

Assembly instructions for kit #9
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Before tightening the switch nut align the dial as shown:
31.Align the knob with R (standard reed switch motor) and tighten the set screw.
Your motors are ready to use! Keep in mind that only regular reed switch motor should
work on 1.5 Volts (1 battery); all the others require at least 3 Volts.
If your switch does not work check all the wiring. If one of the motors does not work –
check corresponding Troubleshooting section of our web site.

Assembly instructions for kit #9
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Appendix A. Electrical diagram of the Kit #9.