NOVAK HV MOTOR - WIRING & GEAR SELECTION User manual

P1P4
• WATER & ELECTRONICS DON’T MIX Never allow water, moisture, or
other foreign materials to get inside motor, or on PC boards.
• CHECK MOTOR SCREWS Check all motor screws for loosening.
The 3 main 4-40 socket screws on the shaft end of motor may
become loose after a few runs of motor & will need to be tightened.
• NOVAK MOTORS WITH NOVAK ESCs ONLY The HV series of
motors have been specially designed for use with the sensor-based
HV-Maxx Brushless ESC Only! Use Novak sensor-based motors with
Novak brushless ESCs with higher wattage rating than the motor.
• ALWAYS INSULATE EXPOSED WIRING to prevent short circuits.
• NO SOLVENTS Exposing the motor to any type of solvents can
damage the exposed material.
PRECAUTIONS
HV-SERIES MOTOR SPECS
Motor Diameter .............................................. 1.41” [35.8 mm]
Motor Length ................................................. 2.84” [72.1 mm]
Motor Weight (w/o heat sink) .................... 8.4 ounce [295 grams]
Motor Commutation ............................ Sensor-Based Electronic
Motor Magnet Material ................ Neodymium [1pc/multi-pole]
GEAR SELECTION (Important)
HV4400 Motor @ 12 cells (14.4VDC)
With the HV4400 motor start with 2 teeth lower pinion gear
than the “stock” gearing for most 1/10th scale monster trucks
like the Traxxas E-Maxx & Kyosho Twin Force.
Because of the broader power band of brushless motors, you can
go with 1-3 tooth higher pinions than the above recommendation
for more top speed, but remember that going with 3 or more
teeth higher will produce excessive ESC & motor heating
. Be sure
to check the ESC operating temperature after making
any gearing
adjustments--the HV-Maxx ESC is designed to operate comfortably
between 160ºF and 180ºF (warmer than typical brush-type ESC).
You will want the final drive ratio in the vehicle to be:
22 : 1 for Monster Trucks @ 12 cells
9 : 1 for Off-Road Buggies @ 6-7 cells
12.3 : 1 for Off-Road Stadium Trucks @ 6-7 cells
Higher final drive ratios give longer run time at the expense of top speed. Lower
ratios result in higher ESC temperatures--too low may result in thermal shut-down.
VEHICLE SPUR HV4400 PINION
Traxxas E-Maxx 70* 14-16
Kyosho Twin-Force 50st 15-16
Tamiya TXT-1 40st 15st
st = stock gear size *= bigger than stock
Note: The above chart shows basic starting points for gearing vehicles with
standard size tires--See our website for extended gearing information.
MOTOR & ESC WIRING
REPLACEMENT POWER CAPACITOR INSTALLATION
•Insulate capacitor leads with heat shrink tubing.
•Solder capacitor’s NEGATIVE(–) lead {shorter lead on
capacitor} to the HV-Maxx’s BLACK PowerCap wire that
comes from the smaller hole on ESC’s BAT.2(-) tab.
• Solder capacitor’s POSITIVE(+) lead to RED PowerCap wire
coming from smaller hole on ESC’s BAT.1(+) tab.
HARD WIRING ESC TO BATTERY PACK
•DOUBLE CHECK polarity & battery number of each
connection before soldering to packs--
INCORRECT WIRING
WILL DAMAGE ESC (check tab I.D. on ESC labels).
{
Put a tie-wrap or tape around each set of battery wires
}
coming from ESC to avoid possible incorrect wiring.
• Cut ESC’s BLACK BAT.1(-) power wire to the desired length
& strip 1/8-1/4” of insulation off the end. Solder to
NEGATIVE(–) of battery #1 (6-7 cell pack). Repeat for BLACK
BAT.2(-) power wire going to NEGATIVE(–) of battery #2.
• Cut RED BAT.1(+) power wire to length & strip 1/8-1/4” of
insulation off end. Solder to battery #1 POSITIVE(+). Repeat
for RED BAT.2(+) wire going to battery #2 POSITIVE(+).
REPLACING POWER WIRES AT ESC & MOTOR
The HV-Maxx ESC comes factory wired to the brushless motor
& battery connectors. For custom installation or for
replacement of the Silicone power wires:
•Remove power wires from PCB solder tabs
(remove ESC
from model to get access to bottom side of solder tabs)
. Use a
soldering iron to apply heat to the power wire’s solder joint
on bottom side of solder tab, while gently pulling up on
the wire to remove it from the hole in the PCB.
•Replace power wires by stripping 1/8-1/4” of insulation
from end of the new wire. Tightly twist strands of wire
&
insert into proper solder tab’s hole
(tabs are identified on the
ESC case labels & on the end cap of the motor--see below)
. Use
soldering iron to apply heat to exposed wire
that extends
past bottom of PCB, and begin adding solder to tip of
soldering iron and to wire. Add just enough solder to form
a clean & continuous joint from the plated area of solder
tab up onto the wire. Use side cutters to trim remaining
(now soldered) wire from below solder tab (about 1/16”
above PCB)--make sure no wire strands have strayed to an adjacent
solder tab as this can result in short-circuiting & damage to the
electronics, which will void the product’s warranty.
•Be sure to solder phase wires to appropriate tabs on Motor (A/B/C)•
A = BLUE
B = YELLOW
C = ORANGE
• Note: Power wires can also be soldered flat on the solder tabs.
Strip 3/16-1/4” of insulation off end of the new wire. Tightly
twist strands of wire & tin with solder. Lay end of wire flat
on solder tab & use soldering iron to heat the end of the wire .
Add solder to form a clean solder joint between wire & tab.
I MPORTANT NOTE: DO NOT OVERHEAT SOLDER TABS
Prolonged/excessive heating of solder tabs will damage PCB.
CHANGING BATTERY CONNECTORS
If you want to change Tamiya-style battery connectors on
the ESC, we recommend using high-quality/low-resistance
connectors, such as Dean’s Ultra Plug. Use female connectors
on battery packs to avoid shorting. Change one connector
at a time to avoid incorrect wiring (check tab I.D. on ESC labels).
Always use a connector that can not be connected backwards!
motor
phase
wire
tab I.D.
text
A
B
C
TAMIYA TXT-1 INSTALLATION KYOSHO TWIN-FORCE INSTALLATION
#55-3410-1 12-2004
HV-Maxx screwed
into stock ESC
location
Strut that houses rear bearing of lay shaft must be
narrowed as shown here for motor clearance--
Dremel can be used to remove plastic.
Power Capacitor
tie-wrapped to “X”
in shock tower
ON/OFF switch
screwed to hole
in chassis
KYOSHO TWIN-FORCE MODIFICATIONS
Upper screw hole on motor plate must be elongated toward middle of vehicle by 0.1”, and rear lay shaft bearing strut must be narrowed for motor clearance.
REMOVE
PLASTIC
HERE FOR
CLEARANCE
ELONGATE MOTOR
SCREW HOLE
Mount motor on
either side
HV-Maxx double-sided
taped onto radio plate Power Capacitor
tie-wrapped to chassis
ON/OFF switch
screwed to hole
in chassis
Motor can mount on either left
or right side of motor mount.
Be sure to position motor’s
Direct-Solder PCB tabs horizon-
tally & face toward center of
vehicle to avoid interference
with suspension components
when compressed.
BAT.1(-) shorted
to BAT.1(+) for
single battery
pack operation
hv motor/wIrINg sheet
HV4400 SPECIFICATIONS #3410
Motor Power Rating 375 watts (@14.4VDC)
Motor Kv 4400 RPM/volt DC
Motor Kt 0.67 inch-ounce/amp

P3P2
TRAXXAS E-MAXX RECOMMENDED INSTALLATION
For installation in the Traxxas E-Maxx, we recommend installing the HV-Maxx in the stock speed control mounting position with the front of the ESC facing the pinion/spur gear cover--this way the cover can still be removed without removing the speed control from the vehicle. The HV-Maxx system comes ready to install in the E-Maxx--the motor heat sink is aligned for installing the motor on the left side of the vehicle as shown here. The included #4x1” self-tapping screws will go through the fan bracket, the ESC’s mounting ears, and thread directly into the E-Maxx’s stock ESC mounting holes in the chassis.
HV brushless
motor mounted
in left-hand
motor position
Direct-Solder
PCB wire tabs for
phase/power
wires on motor
HV-Maxx with
cooling fan
mounted in stock
ESC location
#4x1” self-tapping
screws into stock
mounting holes
Motor hole cover
screwed in place of
2nd motor to keep
debris out of gears
& slipper
SENSOR HARNESS WIRING
Should any of the 26G Teflon wires pull out of the connector on
the motor’s sensor harness, re-insert them in the appropriate slot
in the connector as shown below. There is a small plastic tab
that grabs a small raised barb on the back of the metal socket
crimped to the Teflon wire’s end. The plastic tab should be
checked to make sure it has not deformed excessively before
inserting the socket into the plastic connector housing.
black
orange
white
plastic
tabs
red
blue
green
metal
barbs
raised
metal
barb
metal socket
on end of Teflon
sensor harness wires
SERVICE PROCEDURES
Review instructions before sending motor for service--motor may
appear to have failed when other problems exist.
After reviewing the instructions, if you feel the motor 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 the
SERVICE section of Novak website. Fill out the needed information
and return it with the Novak product.
PHONE/FAX/E-MAIL: Contact our customer service department
by phone, fax, or e-mail (see CUSTOMER SERVICE section below) ,
and they will supply you with current service options.
WARRANTY SERVICE: For warranty work, you MUST CLAIM
WARRANTY on the product SERVICE FORM and include a valid,
itemized cash register receipt with purchase date and dealer name
& phone number on it, or an invoice from previous service work.
If warranty provisions have been voided, there will be service charges.
ADDITIONAL NOTES:
•Brushless ESC & 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 product for service, submit a
completed product SERVICE FORM to the dealer and make sure
it is included with the items.
PRODUCT WARRANTY
Novak brushless motors 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, cross-connection of battery/motor power wires, over-
heating PCB solder tabs, damage resulting from thermal overload, splices to
sensor harness, damage from disassembling motor, over-tightening or using too
long of motor mounting screws, tampering with internal electronics, allowing water ,
moisture, or any other foreign material to
enter motor or get onto the PC board,
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
motor or other related electronics, no liability may be assumed nor will be accepted
for damage resulting from the use of this product. Every 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.
©2004 Novak Electronics, Inc. • All Rights Reserved • No part of these
instructions may be reproduced without the written permission of Novak
Electronics, Inc. • All Novak motors are designed & assembled in the U.S.A.
Novak Electronics, Inc.
[phone] • FAX [phone]
M-Th: 8am-5pm (PST) • Fr: 8am-4pm (closed every other Friday)
e-mail: [email protected] • web: www.teamnovak.com
1. MOTOR CAPACITORS & SCHOTTKY NOT NEEDED
Novak brushless motors have built-in motor capacitors, and
like all reversible ESCs, do not use external Schottky diodes.
Schottky diodes damage reversible ESCs & void warranty.
2. CHECK MOTOR SCREW LENGTH
Insert the M3 motor mounting screws that came with your
vehicle through the motor mounting plate in vehicle
. You
need to have no more than 1/8” of screw extending past
the vehicle’s mounting plate (2-4mm). Too little can strip
the threads in the end bell, and any more will cause short-
circuiting/damage inside the motor & will void warranty.
3.
INSTALL PINION GEAR (see GEAR SELECTION on back)
Install pinion gear on motor and position set-screw over flat
on end of shaft. Test fit motor in vehicle to align pinion and
spur gears, then tighten pinion gear on shaft.
4. INSTALL MOTOR IN VEHICLE
• Determine the best routing for sensor harness & motor
power
wire. Some off-road cars may require unsoldering
motor to route wires through the shock tower--refer to the
“WIRING MOTOR TO ESC” section.
• Using the M3 motor screws that came with your vehicle,
attach motor to vehicle’s motor mount using one of the
three sets of threaded mounting holes--select a mounting
position that will avoid short-circuiting of solder
tabs on
conductive surfaces such as aluminum or graphite.
• Check gear mesh for proper amount of play. You want to
have a small amount of free play between the pinion and
spur gears (about the thickness of piece of paper)--check
free play at several positions around the spur gear.
• Avoid using excessive force when tightening motor screws,
as the threaded holes could become stripped.
HOOK-UP INSTRUCTIONS
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 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 bearings (replacement bearing sets
are available in Novak accessory kit #5910 and include bearing
replacement instructions--If you do not feel comfortable changing
the bearing on your own, please contact our Customer Service
Dept. for assistance). A small drop of light oil on the bearings
periodically can help extend bearing life--too much oil will cause
problems, so apply sparingly.
SUPER-FLEX SILICONE POWER WIRE
Novak Super-Flex wire for power wiring. 14 gauge silicone wire in
kit #5500 (36”red/36”black), and 12 gauge silicone in kit #5530
(36”red/36”black).
H-SERIES MOTOR END BELL & BEARING SET
After extensive use, the ball bearings in the end bells of your
brushless motor may need to be replaced. Replacement front end
bell with oversize bearing factory-installed & rear bearing are available
in Novak kit #5910.
ACCESSORIES
Power Capacitor
tie-wrapped to “X”
in shock tower
Motor power wires routed through wire
holds in gear cover & in gap under cover
E-MAXX UPGRADES
After extensive testing, we’ve found the
high-power output from the HV-Maxx
system to be too much for the stock
E-Maxx components. We recommend
the following performance upgrades:
Front & Rear CVDs & CVD out drives
(we used MIP CVDs & outdrives)
Heavy-duty slipper w/spur gear
(we used Robinson’s slipper & 70T spur)
Metal transmission idler gears
*Check our website for more information