NOVAK SS4300 MOTOR User manual

SPECIFICATIONS
PRECAUTIONS
ESC Input Voltage 4-6 cells (1.2 volts DC/cell)
ESC Power Rating 225 Watts @ 25 ° C trans.temp.
ESC B.E.C. Voltage/Current 6.0 volts DC/1.5 amps
ESC Throttle Modes 2 (1 w/Rev. & 1 Fwd/Brk)
Motor Diameter 1.41” [35.8 mm]
Motor Length 2.08” [52.8 mm]
Motor Turns 10 1/2
Motor Kv 4300 RPM/Volt DC
Motor Kt 0.45 Inch-Ounce/Amp
Motor Commutation Sensor-Based Electronic
Motor Magnet Material Neodymium (1pc/multi-pole)
• DISCONNECT BATTERIES WHEN NOT IN USE Always
disconnect the battery pack from the speed control when not
in use to avoid short circuits and possible fire hazard.
• WATER & ELECTRONICS DON’T MIX! Never allow water,
moisture, or other foreign materials to contact ESC or motor.
• 4 TO 6 CELLS ONLY Never use fewer than 4 or more than 6
cells (7.2 volts DC) in the main battery pack.
• POWER CAPACITOR REQUIRED The attached external power
capacitor MUST be used with the Super Sport 10.5.
Failure to use Power Capacitor will damage speed control and
void the warranty!
• CHANGING VEHICLE GEARING CAN CAUSE OVERHEATING
The Super Sport 10.5 has been specially built for this vehicle’s
stock gearing--any changes may result in thermal shut-down.
•CHECK MOTOR SCREWS Check all motor screws for
loosening. The 3 long main screws on the shaft end of motor
& the 3 flat head screws on the back end may loosen after a
few runs of the motor, and need tightening.
• NOVAK MOTORS ONLY The Super Sport 10.5 ESC has been
specially designed for use with sensor-based Novak Brushless
Motors Only! You may replace motor with any Novak sensored
brushless motor with 10
1/2turns or more.
• NO REVERSE VOLTAGE! Reverse battery polarity will damage
the speed control and void the warranty.
• NO SCKOTTKY DIODE! Never use Schottky diodes with
brushless ESCs--use will damage ESC & void warranty.
• TRANSMITTER ON FIRST Always turn on the power of your
transmitter first so that you will have control of the radio
equipment when you turn on the speed control.
• INSULATE WIRES Always insulate exposed wiring with heat
shrink tubing to prevent short circuits.
• NO SOLVENTS Exposing the speed control or motor to any
type of solvents can damage the exposed material.
• NO CA GLUE Never use cyano-acrylate (CA) glue on the
speed control or motor. Exposing the ESC or motor to CA
glue will damage the electronics and void the warranty.
OWNER’S MANUAL
SUPER SPORT 10.5 ESC & SS4300 MOTOR
Novak Sensor-Based Brushless Motor System
Congratulations on your purchase of a vehicle that is
equipped with a state-of-the-art sensor-based brushless mo-
tor system. Now you too will enjoy the low-maintenance,
high-efficiency performance of brushless motors that are de-
signed specifically for R/C cars.
We’ve combined the racing technology of our top of the
line speed controls with the efficiency of sensor-based
brushless motors to bring you the Super Sport 10.5 Brushless
Electronic Speed Control (ESC) & the SS4300 Brushless Motor,
giving you a sport-level brushless system with excellent low
speed driveability, extended run time, great torque available
over a broad power band, and Novak relaibility.
Equipped with Novak’s Variable Throttle Step Technology for
the smoothest throttle response, One-Touch Set-Up for ease
of programming, and the security of Radio Priority Circuitry,
the Super Sport 10.5 has it all!
Benefits of sensor-based brushless motor design:
• CONSTANT ROTOR POSITION KNOWLEDGE Always
knowing what angle the rotor is at, allows instantaneous
response and smooth transitions from neutral to drive.
• SMOOTH/CONTROLLED LOW SPEED DRIVEABILITY
Rotor positioning is key to smooth acceleration without
delivering abrupt and uncontrolled bursts of power.
• STRONG & CONSISTENT BRAKES & STARTING TORQUE
Rotor position knowledge results in consistent starts and stops,
without hesitation or inconsistent lag times before
acceleration or braking.
•
LOCKED ROTOR & THERMAL PROTECTION Temperature &
position sensors in motor provide unparalleled protection for
your investment. Allowing you to run pack after pack without
worrying about overheating the motor, ESC, or magnets.
ACCESSORIES
REPLACEMENT POWER CAPACITOR
[Novak kit #5677]
The Super Sport 10.5 comes with a factory-installed Power Capacitor,
and MUST BE USED to maintain cool/smooth operation-- Note: We highly
recommend using Novak Power Capacitors, as we have done extensive testing &
research to find Power Capacitors with the very best quality factors––other capacitors
with similar ratings will not provide equal protection. Larger Novak capacitors are OK.
Replacement Super Sport 10.5 Power Capacitor is available in kit #5677.
SUPER-FLEX SILICONE 14G WIRE
[Novak kits #5500 & 5508]
Novak Super-Flex power wire. 14 gauge silicone wire in kit #5500 (36”red
& 36”black) and kit #5508 (2 each of 9”red/black/blue/yellow/orange) .
INPUT SIGNAL HARNESS
[Novak kits #5315 & 5320]
User-replaceable input signal harness is available in both short & long
lengths. 4.5” harness in Novak kit #5315, and 9.0” harness in kit #5320.
SS4300 MOTOR BEARING SET
[Novak kit #5904]
After extensive use, the ball bearings in the end bells of your brushless
motor may need to be replaced.
Replacement front & rear bearings are available in Novak kit #5904.
SERVICE PROCEDURES
Before sending in your Super Sport 10.5 brushless speed control or
SS4300 brushless motor for service, review the Trouble-Shooting
Guide and Owner’s Manual. The ESC or motor may appear to have
failed when other problems exist.
After reviewing the Owner’s Manual, if you feel the system requires
service, please obtain the most current product service options and
pricing by one of the following methods:
WEBSITE: Print a copy of the PRODUCT SERVICE FORM from SERVICE
section of the Novak website. Fill out needed information on form
and return it with the Novak product requiring service.
PHONE/FAX: If you do not have access to the internet, contact
our customer service department by phone or fax as listed in the
CUSTOMER SERVICE section below, and they will supply you with
current service options.
WARRANTY SERVICE: To receive warranty work, you MUST CLAIM
WARRANTY on the PRODUCT SERVICE FORM & include a valid,
itemized cash register receipt with purchase date on it, or invoice
from previous service work.
ADDITIONAL NOTES:
•The Super Sport 10.5 speed control and the SS4300 brushless
motor should be returned together.
• Hobby dealers or distributors are not authorized to replace Novak
products thought to be defective.
• If a hobby dealer returns your speed control & motor for service,
submit a completed PRODUCT SERVICE FORM to the dealer and
make sure it is included with the items.
• Novak Electronics, Inc. does not make any electronic components
(transistors, resistors, etc.) available for sale.
PRODUCT WARRANTY
The Super Sport 10.5 brushless ESC & SS4300 brushless motor are guaranteed to
be free from defects in
materials or workmanship for a period of 120 days from the
original date of purchase
(verified by dated, itemized sales receipt). Warranty does not
cover incorrect installation,
components worn by use, damage from using fewer
than 4 or more than 6 cells (1.2 volts DC/cell) input voltage, cross-connection of
battery/motor power wires,
overheating solder tabs, reverse voltage application,
damage resulting from thermal
overload, damage from incorrect installation of
FET servo or receiver battery pack, not installing or incorrect installation of a Novak
power capacitor on the ESC,
splices to input harness, damage from excessive force
when using the One-Touch/SET
button or from disassembling case or motor, tam-
pering with internal electronics,
allowing water, moisture, or any other foreign
material to enter ESC or get onto the
PC board, incorrect installation/wiring of input
plug plastic, allowing exposed wiring
or solder tabs to short-circuit, or any damage
caused by a crash, flooding, or act of God.
In no case shall our liability exceed the product's original cost. We reserve the
right to modify warranty provisions without notice.
Because Novak Electronics, Inc. has no control over the connection and use
of the
speed control & motor or other related electronics, no liability may be assumed
nor will be accepted for damage resulting from the use of this product. Every
speed control & motor is thoroughly tested and cycled before leaving
our facility
and is, therefore, considered operational. By the act of connecting/
operating speed
control, the user accepts all resulting liability.
CUSTOMER SERVICE
NOVAK ELECTRONICS, INC.
Monday-Thursday: 8:00am-5:00pm (PST)
Friday: 8:00am-4:00pm
[phone] • FAX [phone]
e-mail: [email protected]
web: www.teamnovak.com
©2006 Novak Electronics, Inc. • All Rights Reserved • No part of this Owner’s Manual
may be reproduced without the written permission of Novak Electronics , Inc. • Super
Sport 10.5 Brushless ESC, SS4300 Brushless Motor, Locked Rotor Detection Circuitry,
Variable Throttle Step Technology, Polar Drive Technology, Radio Priority Circuitry, &
One-Touch Set-Up are all trademarks of Novak Electronics, Inc. • All Novak ESCs &
motors are designed &
assembled in the U.S.A.
Printed in the U.S.A. 2/2006 • #55-1010-1

The Super Sport 10.5 ESC is equipped with dual throttle
programs: Forward, Brake, & Reverse (Mode 1) , and Forward
& Brake only (Mode 2). By disabling the reverse feature of
the Super Sport 10.5, the speed control can be set-up for
forward and brake only operation, which may be useful if
you are going to use this vehicle at your local track and
they do not allow reversible ESCs to be used during racing.
Selecting Throttle Mode with TRANSMITTER ON
With transmitter ON & ESC connected to receiver and battery:
1. TURN ON THE SPEED CONTROL’S POWER
2. PRESS & HOLD SPEED CONTROL’S SET BUTTON
With the transmitter throttle at neutral, press and hold
the SET button on Super Sport 10.5, and continue
holding button until all 4 status LEDs turn on.
3. RELEASE SPEED CONTROL’S SET BUTTON
All status LEDs will flash together. The number of times
the LEDs flash indicates the Throttle Mode selected.
4. PRESS & RELEASE SET BUTTON TO SELECT MODE
Each press will change the Throttle Mode
.
5. WAIT FOR SPEED CONTROL TO EXIT PROGRAMMING
When the speed control’s SET button is not pressed for
about 3 seconds, the
ESC loads the selected Throttle Mode
into memory and exits programming--the red status LED
will turn solid red indicating that the speed control is back
at neutral and ready to go.
REMEMBER: Whenever One-Touch set-up is performed, ESC automatically reverts to
factory default settings & the Throttle Mode reverts to Mode1 (Fwd, Brake, & Rev).
TROUBLE-SHOOTING GUIDE
This section describes possible ESC problems, causes, and solutions.
Steering Channel Works But Motor Will Not Run
• Make sure motor sensor harness is plugged into ESC––check for
damaged wires. Green & red status LEDs will be blinking fast.
• Make sure input signal harness is plugged into ESC & throttle
channel of receiver. Check throttle channel operation with a servo.
Check wiring sequence of receiver signal harness. Green & red
status LEDs will both be on solid.
• ESC may have shut down due to locked rotor detection––return
throttle to neutral position to regain motor control––check
vehicle’s drive train for free operation. Blue & green status LEDs
will both be blinking.
• ESC or motor may have shut down due to thermal overload––
allow system to cool down & return throttle to neutral position
to regain motor control––check for free operation of drive train
for possibly overloading that could result in overheating. Blue
status LED will be blinking until cooled down.
• ESC may have shut down due to thermal overload or locked
rotor detection & ESC’s neutral point is too far off to sense that
throttle has been returned to neutral.
Blue & green status LEDs blinking indicates Locked Rotor Detection.
Blue LED blinking indicates thermal shut-down.
• Possible internal damage––Refer to Service Procedures.
Receiver Glitches/Throttle Stutters During Acceleration
• Receiver or antenna may be too close to speed control, power
wires, or battery.
• Bad connections––Check wiring, connectors, and sensor harness.
• External Power Capacitor damaged or not installed .
Motor and Steering Servo Do Not Work
• Check wires, receiver signal harness wiring & color sequence,
radio system, crystals, battery/motor connectors, & battery pack.
• Possible internal damage––Refer to Service Procedures.
Speed Control Runs Hot
• Gear ratio has been changed and is too low––Increase gear ratio
(see ‘VEHICLE GEARING’ section).
Model Runs Slowly/Slow Acceleration
• Gear ratio has been changed and is too low––Increase gear ratio
(see ‘VEHICLE GEARING’ section).
• Check battery connectors––Replace if needed.
• Incorrect transmitter/ESC adjustment––Refer to ‘ONE-TOUCH
PROGRAMMING’ section.
• External Power Capacitor damaged or not installed .
• Motor bearings worn––Refer to ‘MOTOR MAINTENANCE’ section.
ESC Is Melted Or Burnt/ESC Runs With Switch Off
• Internal damage––Refer to Service Procedures.
*For more assistance call our Customer Service Department.
MOTOR MAINTENANCE
• CHECK MOTOR SCREWS Check all motor screws for
loosening at regular intervals, just like other hardware on
your vehicle. Note: The 3 main 4-40 socket head screws on the
shaft end of the motor may become loose after a few runs of the
motor and will need to be tightened. Also check the 3 flat head
screws securing the end cap on the back of the motor.
• CHECK MOTOR BEARING WEAR After extensive use,
the ball bearings in the end bells of your brushless motor
may need to be replaced
. While the design of the motor
will keep the majority of the debris out of the bearings, some
debris may get in, and eventually wear will occur. If the shaft
will not spin freely, you may need to replace the motor
bearings (replacement bearings available in Novak kit #5904--
Contact
our Customer Service Dept. if you do not feel comfortable changing
the bearing on your own ) . A small drop of light oil on the
bearings periodically can help extend bearing life--too much
oil will cause problems, so apply sparingly.
• PERIODIC MOTOR CLEANING We recommended that
you disassemble the motor and clean the inside of it at
regular intervals. About once a month, if you subject the
motor to heavy weekly usage (like club racing once a week),
i
s a good schedule. Every few months if you used less heavily.
CLEAN INSIDE MOTOR: Remove 4-40 socket head cap
screws on the shaft side & remove end bell. Next, remove
the rotor by pulling it out by the shaft--be careful not to
damage magnet or lose shaft spacers (if epuipped with). Use
compressed air to blow debris off rotor and out of the
inside of the motor--DO NOT USE SOLVENTS. Reassemble,
making sure the short spacer is on the pinion side of rotor.
CLEAN THE REAR BEARING: Remove 4-40 flat heat screws
and remove the black plastic end cap (cap may stick--pry
up gently). Wipe off the rear bearing & replace end cap.
SENSOR HARNESS WIRING
Should any of the 26G Teflon wires pull out of the connector
on the end of the motor’s sensor harness, replace them into
the appropriate slot in the connector as shown below. The
connector has small plastic tabs that grab a small raised barb
on the back of the metal socket that is crimped onto the ends
of the Teflon wire. The plastic tab should be checked to make
sure it has not deformed excessively before inserting the
socket into the plastic connector housing.
Note: If the motor’s sensor harness becomes damaged, contact the
Novak Customer Service Department.
black
orange
white
plastic
tabs
red
blue
green
metal
barbs
raised
metal
barb
metal socket
on end of Teflon
sensor harness wires
The Losi vehicle this brushless speed control and motor came
with used 19 tooth pinion gear and a 90 tooth spur gear.
The stock gearing is for general outdoor use--If the model
is going to be run in a confined area, a smaller pinion gear
may be necessary to prevent over-heating.
{If operating temperatures get too high, the ESC and/or motor may thermally
shut down & may cause internal damage that voids product warranty}
Similarly, increasing the pinion size can cause over-heating.
The Super Sport 10.5 ESC and SS4300 motor are designed to operate
comfortably from 160ºF-170ºF (warmer than a typical brush-type ESC/motor) .
VEHICLE GEARING (Important) REVERSE DISABLE
NOTE: If transmitter’s throttle end point adjustments are
changed, the ESC’s One-Touch programming will need to
be performed. If you do not
, you might not get optimal
performance from your brushless ESC/motor system.
With ESC connected to receiver & a charged battery pack:
1. TURN ON THE TRANSMITTER’S POWER
2. PRESS & HOLD SPEED CONTROL’S SET BUTTON
3. TURN ON THE SPEED CONTROL’S POWER
With transmitter throttle at neutral, and still pressing the
SET button slide the ON/OFF switch to ON position.
4. CONTINUE HOLDING SET BUTTON UNTIL RED LED IS ON
5. RELEASE SET BUTTON AS SOON AS LED TURNS RED
6. PULL TRANSMITTER THROTTLE TO FULL-ON POSITION
Hold it there until the green status LED turns solid green.
Note: Motor will not run during programming even if connected.
7. PUSH TRANSMITTER THROTTLE TO FULL-BRAKES
Hold it there until the green status LED blinks green.
8. RETURN TRANSMITTER THROTTLE TO NEUTRAL
Red status LED will turn solid red, indicating that the
speed control is at neutral and that proper programming
has been completed.
If you experience any problems during One-Touch programming,
turn off the ESC and repeat above programming steps.
ONE-TOUCH PROGRAMMING