ESC Potting and Firmware update

Tools Required

• T6 driver

• Wire stripper

• Klauke Crimping tool

• Scissors

• Tweezers

• 20ml Plastic syringe

• TMotor Data Link

• TMotor Datalink software

• USB C Cable

• Two M6x16mm Bolts

• Two M6 Nuts

• Bench power supply with Crocodile clips

A pouch of potting compound should be placed in the fridge the night before a batch is due to be potted. The colder temperature will give a slightly longer working time to the mixture.

Parts Picklist

• T-Motor Alpha 60A 12s V1.2 ESC

• Custom T-Motor Case Top PRD-MNA-00040063

• Custom T-Motor Case Bottom PRD-MNA-00040061

• Panduit 14-10 AWG Lugs

• Heat Shrink

• Masking Tape

• BluTac

• Loctite

• 10x10 Thermal Pad

• 30x40 Thermal pad

• Potting compound

Cut 10mm off the red power lead and black ground lead to remove the pre-soldered section. Strip 10mm off the wire Add the 14-10 AWG Panduit lug onto the wire ensuring it is all the way flush with the silicon sheath Using the Klauke crimping tool on the second tooth crimp on the lug Apply 20mm of heat shrink tubing as per the image

This should be set to 24v 2a

Once removed ensure all of the original thermal pad material has been cleaned off the ESC. Remove the three rubber gromets from the orange ESC wires and keep them aside as they will be re-used

Apply Masking tape around the top edge of the new ESC Casing as per the images Gently use a Countersink drill bit to clear the tape from the 3 holes in the ESC casing

When installing the black rubber gromets, ensure the thicker side of the gromet is on the outside of the ESC. Install the 30x40 thermal pad into the ESC casing with the 'Textured' side facing up.

Peel off the plastic covering on the 30x40 thermal pad. Push the 3 orange ESC wires through the gromets and slide the unit into the casing while taking care not to damage the thermal pad. Apply the 10x10 thermal pad as per the image.

Insert a pea sized piece of blutac onto the red esc wire using a blunt tool to press it to hold the ESC down into the casing. This will prevent the ESC from rising up while pouring in the potting compound.

Roll up and cover the power wiring and molex connectors in a piece of tape and plastic wrap to protect them from any overspill of potting compound.

Add Loctite to all of the ESC screws, peel off the protective layer on the 10x10 thermal pad.

ESCs should be potted in batches of 17. One 250g pouch of Potting compound will fill 2 aircrafts worth of ESCs in a single batch plus one extra ESC which will be kept aside for testing from each batch.

Remove the black dividing strip from the Potting compound pouch Push one side of the mixture to break the plastic divider and begin mixing It is best to mix the compound flat on the desk with a round object being used as a rolling pin as working it by hand will warm it up prematurely and decrease the working time. The compound should be mixed thoroughly for 3 mins turning into a white liquid with no streaks

Place the ESCs on an Oven shelf which should be wrapped in release film The ESCs should be propped up on a piece of cardboard for the initial pour to assist the liquid in flowing under the PCB Snip a small corner from the bag of mixed compound and pour the liquid into the casing starting from the bottom at the orange wires. Drizzle the liquid up across the pcb taking care not to cover the thermal pad Fill the casing until the compound is level with the top of the casing at the end where the orange wires are. Remove the Cardboard prop. Install the top casing ensuring all of the wires are in their respective slots and not being pinched by the lid. Install all 4 pre loctited screws. Using the 20ml plastic syringe top off the ESC with compound until a small amount flows out the side.

Insert the shelf of Potted ESCs into the oven and run the program for ESC curing of 60deg Celsius for 4.5hours

Once the curing process is finished remove all masking tape from the ESCs Use a sharp blade to gently scrape off any excess compound around the top fill hole.

ESC QR code

ESC QR code

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ESC QR code

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ESC QR code

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ESC QR code

ESC QR code

ESC QR code

ESC QR code

ESC QR code

ESC Potting Batch No:

Using a scalpel gently lift the black tab on each molex connector to release the female pins from the plastic component.

Using a wire snips, trim off the female molex terminal from the Red wire in the TLM ribbon