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NetGain Motors AmP 8, Owner'S Manual, Page: 3 / 34

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NetGain Motors AmP 8 Owner'S Manual Download Page 3

RE: Your new 

NetGain Motors, Inc.

  DC Motor 

It is with great pleasure that everyone at 

NetGain Motors, Inc.

.

 welcomes you to the 

AmP 

 

™

 

and 

WarP 

™

 

motors

 

 

owner's family! We would also like to “

Thank You”

 for your purchase. 

Since electric motors are different from internal combustion engines, this Owner's Manual is 
being sent to you to provide information on running and caring for your new motor. Please read 
it carefully and follow the suggestions that will provide for years of great performance from 
your new motor.  

This Owner's Manual contains the new motor warranty, our dealer's safety information sheet, 
wiring tips bulletin, heat and rpm protection bulletin, care and maintenance information sheet, 
bench test procedure bulletin and other information of interest and importance.  If you purchased
an AmP Motor your motor warranty will be provided by the Advanced Motors & Drives 
Warranty.  All other motors are covered by Warfield Electric Company, Inc.

There is also a substantial amount of content that may be obtained at our website:  
http://www.go-ev.com

Along with your dealer,  we definitely want to help make your EV project a success, so please 
let us know if you have any questions about your motor, safety, wiring or anything else. We'll 
help you or find resources that can help.

Again, we thank you for your motor purchase – we  wish you success in your EV project!

WarP 

™

 

Motors

  

– 

TORQUE ABOUT IT!

George Hamstra

NetGain Motors, Inc.

  

President

Summary of Contents for AmP 8

Page 1: ...Owner s Manual for and ...

Page 2: ... correct installation and operation for all equipment The seller has no opportunity to supervise the application installation or maintenance of the components used nor to supervise and inspect the replacement of the motors used Therefore the installer agrees that all motors will be used solely at the purchaser s risk The purchaser will indemnify and hold the seller its owners and its employees or ...

Page 3: ...bulletin heat and rpm protection bulletin care and maintenance information sheet bench test procedure bulletin and other information of interest and importance If you purchased an AmP Motor your motor warranty will be provided by the Advanced Motors Drives Warranty All other motors are covered by Warfield Electric Company Inc There is also a substantial amount of content that may be obtained at ou...

Page 4: ...ty whether in contract or in tort or under any other legal theory arising out of warranties representations instruction or warnings or any lack or inadequacy thereof deficiencies failures or defects of any kind or from any cause shall be limited exclusively to repairing or replacing parts during normal business hours under the provisions stated above All liability for damages including but not lim...

Page 5: ...ts in workmanship and material during the Warranty Period and subject to Limitations and Exclusions as delineated in this document 3 Warranty Period The Warranty Period begins on the manufacturing date of products shipped to the user The basic standard Warranty Period is of 1 one year or for the first 2000 two thousand hours of use whichever occurs first A Warranty Period longer than 1 one year ma...

Page 6: ...ial of the claim 5 4 If Customer disagrees with the determination Advanced Motors Drives Inc and Customer will discuss the determination in good faith and solve the warranty claim amicably If the determination cannot be resolved amicably then Item 9 of the Warranty Policy shall apply 6 Remedy 6 1 Approved warranty claims Advanced Motors Drives Inc will credit the customer with an amount agreed wit...

Page 7: ... product if specifically designed and or manufactured by Advanced Motors Drives Inc for the Customer s use or purpose The warranty set forth above is given in satisfaction of any and all obligations or liabilities of Advanced Motors Drives Inc to any Customer or any third party with respect to the product whether such liabilities or obligations arise out of contract negligence strict liability tor...

Page 8: ...uld result in harm to people or the motor Absence of a load is considered misuse and could prove dangerous to anyone in the vicinity and void the motor warranty Portions of the motor may become hot and proper precautions must be taken Motors are heavy and are likely to become damaged if dropped or cause damage to anything they fall upon including people and body parts Use extreme caution when work...

Page 9: ...tive in further dissipating motor heat and additionally clears carbon dust from the brushes which reduces risk of flash over and would be damage AmP and WarP motors are designed with an internal fan to provide cooling and motor protection during normal operation All AmP and WarP motors are also configured with a temperature snap switch as a standard item normally open for early warning of an overh...

Page 10: ...plus brush wear in1 Heavy duty vibration resistant stainless steel brush springs Pre drilled advanced timing holes for higher performance Insulation that exceeds Class H temperature rating Best in class patented varnishing process Voltage ranges starting at 48 Volts Interlocking commutator construction High peak motor efficiency Dynamically balanced armatures Hand made in the U S A by experts 1 Th...

Page 11: ... TO HOLD YOUR VEHICLE ON A HILL THIS WILL STALL THE MOTOR AND CAUSE IT TO SCORCH THE COMMUTATOR AND WILL VOID THE WARRANTY A STALLED MOTOR WILL DRAW AS MANY AMPS AS IT CAN AND RESULT IN RAPID OVERHEATING OF THE COMMUTATOR AND WILL VOID THE WARRANTY A STALLED MOTOR WILL NOT BE COVERED BY WARRANTY STALLING WILL BURN THE COMMUTATOR BARS AND IS CLEARLY VISIBLE DURING INSPECTION FOR WARRANTY WARM COMMU...

Page 12: ...r both rotations AmP and WarP motors except the WarP 13 should ALL be jumpered according to these instructions battery polarity does not matter For CCWDE rotation wire as follows CCWDE preferred connection method Connect A1 to S1 Connect A2 to one input power terminal and S2 to the other input power terminal CCWDE alternative connection method Connect A2 to S2 Connect A1 to one input power termina...

Page 13: ... Web Site at http www go ev com dealers only Dealer_Manual All motors produced in 2007 will incorporate 2 lifting holes to aid installation These holes will be positioned 90 degrees apart in order to allow better positioning of the terminal studs Broken fins which occasionally occurred on ImPulse 9 and WarP 9 motors due to the placement of advanced timing holes will now be machined during assembly...

Page 14: ...lly be the area of greatest heat build up To protect your motor in this area the normal temperature snap switch is installed Connect it to give the driver a warning light or to automatically open the circuit if it indicates overheating Heating will build slower here but fast action needs to be taken to protect the system 4 Consider setting a temperature of 110 120 degrees C for your action startin...

Page 15: ...snow and ice 2 Design the motor mounting area to allow for good air flow The motor needs a continuous supply of clean fresh air to cool properly 3 Protect the motor from dirty air that may be used to cool it Most airborne grit will act as an abrasive which will eventually cause harm to the internal parts of your motor 4 Clean the brushes and comm area regularly from the dust dirt that occurs durin...

Page 16: ...t least 20 feet away from the motor in a well ventilated area or preferably outside of the building The cables MUST be connected and disconnected in the order shown Connecting sequence 1 Connect cable 1 and cable 2 first 2 Connect cable 3 to power source positive terminal at the power source first NOT at the motor 3 Connect the other end of cable 3 to terminal A1 at the motor which is 20 feet away...

Page 17: ...e vehicle will end up weighing about 1 000 lbs more than it did before the conversion and usually have a range of 20 30 miles Certainly some people have converted vehicles with 50 mile ranges using lead acid but the extra range comes at the expense of load carrying capacity It is best to know and consider the effect of adding 1 000 lbs of weight will have on the vehicles handling and braking capac...

Page 18: ...btain is determined in part by the voltage that is delivered to the motor not necessarily by the voltage that is delivered to the controller When a new off shore manufacturer of controllers entered the market a few years back we were swamped by calls from users of this new 120 Volt 1 000 Amp controller who could not get their vehicles over 30 MPH Users naturally accused the motor of not being able...

Page 19: ...e prefer to provide the Authorized Motor Dealer with the information so that they remain the primary point of contact with the customer In order to assist Authorized Motor Dealers in motor selection we need to be provided with as much of the following pieces of information as possible Battery Pack Information Voltage Internal resistance Discharge capabilities Motor Controller Voltage capabilities ...

Page 20: ...of a direct drive configuration Additionally dual motors will require a more complicated wiring scheme in order to allow for reverse direction movement of the vehicle Dual motor direct drive also decreases the overall electrical efficiency of the system slightly The motors enjoy spinning at 2 000 4 000 RPMs You should always design your conversion so that the normal operating RPMs of the motor are...

Page 21: ...l saturation of the motor occurs Lithium Battery Vehicle Direct Drive Motor Selection3 Motor Vehicle Weight Dual Coupling Motor Vehicle Weight TransWarP 7 1 200 lbs WarP 7 2 400 lbs TransWarP 9 1 600 lbs WarP 9 3 200 lbs TransWarP 11 2 000 lbs WarP 11 4 000 lbs TransWarP 11HV 1 600 lbs WarP 11HV 3 200 lbs The use a transmission allows you to double the figures of the first table Lithium Battery Ve...

Page 22: ...the electric motor Don t try to move the vehicle forward if the motor is spinning in the reverse direction In other words if you are rolling backwards make certain the motor is stopped before applying power to move forward This only pertains to direct drive vehicles In vehicles with a transmission the electric motors are not affected by the direction or movement of the vehicle But even if you have...

Page 23: ...he EV is used near salt water The Nord Lock washers are corrosion resistant Their standard steel washers are zinc flake coated with Delta Protekt and endure a minimum of 600 hours of salt spray test in accordance with ISO 9227 If you have a racing vehicle it is important to use compressed air after EVERY race event in order to help expel carbon dust that accumulates This is important with all brus...

Page 24: ...le AmP WarP TransWarP and ImPulse motors represent our DC line of motors All TransWarP motors have a 32 tooth involute spline shaft that matches the transmission output shaft of a Chevrolet Turbo 400 transmission 2 Where did the AmP name come from The Am portion of the name comes from the name of the motor manufacturer that actually contract manufacturers our motors for us The capital P at the end...

Page 25: ...ve were originally set of two matched motors that were designed to be fitted together and work as a single motor The Pe portion of the name is my thanks to Mike Pethel who helped with the development of this radical design Since we no longer plan to produce these motors we are planning to use the name for our new line of AC motor controllers 5 How do I become a dealer of AmP and WarP Motors You sh...

Page 26: ...e increased performance at higher voltages CAUTION If a motor is advance timed and then powered to run in the opposite direction of the advancement significant arcing and damage could result if high power is applied Re gen should not be attempted with motors that have been advance timed 10 How do I know how much to advance the timing on a motor All new AmP and WarP motors have pre drilled holes th...

Page 27: ... your motors in marine applications Certainly but don t submerge them and protect them from saltwater Also pay particular attention to previous questions It is extremely difficult to create a watercraft with 10 12 hours worth of wide open power with generally available battery technology 16 What are the two wires that come out of the motor case and how do I use them These wires are connected to a ...

Page 28: ...controller could have been used you will need a Zilla 2K for a direct drive application Additionally you must force cool air into direct drive motors if the normal RPMs of the driven vehicle are below 2000 RPMs 20 How do Volts and Amps affect a motors performance Volts RPMs in an almost linear manner If you double the voltage you will double the RPMs of the motor Usually RPMs increase just slightl...

Page 29: ... 250 Amps for 1 hour and 200 Amps continuous We believe these are conservative ratings The difference in the variously sized motors is the amount of torque and RPM at which the torque will be delivered If the ratings of a single motor are exceeded you can divide the figures in and use multiple motors There are additional losses of around 8 10 when using dual motors 24 Where can I obtain an adapter...

Page 30: ...ve You ll also need batteries A battery charger s possibly a battery management system possibly a transmission adapter plate battery boxes enclosures a DC to DC converter a transmission adapter plate lots of cable lugs contactor s connectors gauges and wiring 29 What makes a good conversion vehicle First pick a vehicle you like that is in good condition It is not uncommon for people to keep EVs fo...

Page 31: ...0th of the rolling resistance of rubber on concrete A typical EV will use 144 Volts and 500 to 1000 Amps to get started from a dead stop This is 144 kW of power This would require a VERY large generator probably larger than the EV itself and probably requiring more fuel than the original ICE vehicle My suggestion is that if you really want to attempt this that you only use a generator when the veh...

Page 32: ...car from moving if it is on an incline In an ICE vehicle you always have the engine compression emergency brakes and transmission in Park to keep the vehicle from moving on an incline In an EV you should maintain a parking brake but the motor will spin freely so having a transmission that locks could be a benefit 34 Should I keep the clutch The EV community has always been split on this topic Cert...

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