Novak Brushless Motor (55-3400-1) - Manual

• Rotor Position Knowledge--With ESC & motor continuously synchronized
via the motor harness, the sensor-based system provides instantaneous
throttle response & smooth neutral to drive transitions--NO COGGING.
• Smooth/Controlled Low Speed Driveability--Rotor position knowledge
is key to smooth acceleration--no abrupt/uncontrolled bursts of power.
• Strong/Consistent Brakes & Starting Torque--Rotor position
knowledge results in consistent starts & stops, no lag time or hesitation
before acceleration or braking--this translates to consistent lap times.
• Locked Rotor & Thermal Protection--Position & temperature sensors
inside the motor provide unparalleled protection when used with Novak
brushless ESCs, letting you to run pack after pack without worrying
about overheating the motor, ESC, or magnets when properly set-up.
• Rotor Position Knowledge--With ESC & motor continuously synchronized
via the motor harness, the sensor-based system provides instantaneous
throttle response & smooth neutral to drive transitions--NO COGGING.
• Smooth/Controlled Low Speed Driveability--Rotor position knowledge
is key to smooth acceleration--no abrupt/uncontrolled bursts of power.
• Strong/Consistent Brakes & Starting Torque--Rotor position
knowledge results in consistent starts & stops, no lag time or hesitation
before acceleration or braking--this translates to consistent lap times.
• Locked Rotor & Thermal Protection--Position & temperature sensors
inside the motor provide unparalleled protection when used with Novak
brushless ESCs, letting you to run pack after pack without worrying
about overheating the motor, ESC, or magnets when properly set-up.
SENSOR-BASED DESIGN BENEFITS SENSOR-BASED DESIGN BENEFITS
PRECAUTIONS PRECAUTIONS
NEVER FREE-REV THE MOTOR Free-running your brushless
motor in a no-load condition can result in rotor failure and ESC
transistor damage & will void the product’s warranty!
Never free-rev your system to “see how it runs”, or you may not get to drive it again!
• WATER & ELECTRONICS DON’T MIX Never allow water, moisture, or
other foreign materials to get inside motor, or on PCBs.
• CHECK MOTOR SCREWS Remember to check all motor screws
for loosening after a few runs of the motor.
• NOVAK MOTORS & ESCs FOR BEST RESULTS Use Novak sensored
motors with Novak Brushless ESCs for best performance & protection.
Only use motors with the proper number of turns to match ESC’s rating.
Use of this brushless motor with non-Novak ESCs that advance
motor timing can result in excessive current draw & severe motor
damage that will NOT be covered by the product’s warranty!
• DO NOT use motors with lower turns than the ESC is rated for.
• INSULATE EXPOSED WIRES Use heat shrink tubing to prevent shorts.
• NO SOLVENTS Do NOT expose the motor to any type of solvents.
• SET GEAR MESH PROPERLY Too tight of a gear mesh can result
in motor pinion shaft breakage--be sure to adjust mesh properly.
NEVER FREE-REV THE MOTOR Free-running your brushless
motor in a no-load condition can result in rotor failure and ESC
transistor damage & will void the product’s warranty!
Never free-rev your system to “see how it runs”, or you may not get to drive it again!
• WATER & ELECTRONICS DON’T MIX Never allow water, moisture, or
other foreign materials to get inside motor, or on PCBs.
• CHECK MOTOR SCREWS Remember to check all motor screws
for loosening after a few runs of the motor.
• NOVAK MOTORS & ESCs FOR BEST RESULTS Use Novak sensored
motors with Novak Brushless ESCs for best performance & protection.
Only use motors with the proper number of turns to match ESC’s rating.
Use of this brushless motor with non-Novak ESCs that advance
motor timing can result in excessive current draw & severe motor
damage that will NOT be covered by the product’s warranty!
• DO NOT use motors with lower turns than the ESC is rated for.
• INSULATE EXPOSED WIRES Use heat shrink tubing to prevent shorts.
• NO SOLVENTS Do NOT expose the motor to any type of solvents.
• SET GEAR MESH PROPERLY Too tight of a gear mesh can result
in motor pinion shaft breakage--be sure to adjust mesh properly.
MOTOR MAINTENANCE 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 socket head
screws that hold the motor together may require tightening after
a few runs of the motor. On 540/550-size motors, also check the 3
flat head screws securing the end cap on the back of the motor.
• CHECK MOTOR BEARING WEAR
After extensive use, your motor’s bearings may need replacement.
The motor’s closed design will keep most dirt & debris out, but
some will get in and eventually cause wear. If the shaft does not spin
freely, you may need bearing replacement (replacement front end bell
with factory-installed bearing & rear bearing are available in Novak accessory kits-- If
you feel uncomfortable changing the bearing & end bell, contact our Customer
Service Dept. for assistance) . A small drop of light oil on the bearings
periodically can help extend bearing life--however, too much oil will
attract dirt and will cause problems, so apply sparingly.
• CLEAN INSIDE MOTOR
Periodically remove the front end bell of your motor, remove the
rotor, and blow out the inside of the motor with compressed air.
Be sure not to lose any small shim washers that may be on the ends
of the rotor shaft & keep them in the correct location.
• CHECK MOTOR SCREWS
Check all motor screws for loosening at regular intervals, just like
other hardware on your vehicle. Note: The 3 main socket head
screws that hold the motor together may require tightening after
a few runs of the motor. On 540/550-size motors, also check the 3
flat head screws securing the end cap on the back of the motor.
• CHECK MOTOR BEARING WEAR
After extensive use, your motor’s bearings may need replacement.
The motor’s closed design will keep most dirt & debris out, but
some will get in and eventually cause wear. If the shaft does not
spin freely, you may need bearing replacement (replacement front end
bell with factory-installed bearing & rear bearing are available in Novak accessory
kits-- If you feel uncomfortable changing the bearing & end bell, contact our
Customer Service Dept. for assistance) . A small drop of light oil on the
bearings periodically can help extend bearing life--however, too
much oil will attract dirt and will cause problems, so apply sparingly.
• CLEAN INSIDE MOTOR
Periodically remove the front end bell of your motor, remove the
rotor, and blow out the inside of the motor with compressed air.
Be sure not to lose any small shim washers that may be on the ends
of the rotor shaft & keep them in the correct location.
NOVAK ELECTRONICS, INC.
Monday-Friday: 8am-5pm (PST) • (949) 833-8873 • FAX (949) 833-1631
e-mail: [email protected] web: www.teamnovak.com
©Novak Electronics, Inc. Irvine, CA, U.S.A. • Printed 4/2012
No part of these instructions may be reproduced without the written permission of Novak
Electronics, Inc. All Rights Reserved. Novak motors are proudly designed in the U.S.A.
NOVAK ELECTRONICS, INC.
Monday-Friday: 8am-5pm (PST) • (949) 833-8873 • FAX (949) 833-1631
e-mail: [email protected] web: www.teamnovak.com
©Novak Electronics, Inc. Irvine, CA, U.S.A. • Printed 4/2012
No part of these instructions may be reproduced without the written permission of Novak
Electronics, Inc. All Rights Reserved. Novak motors are proudly designed in the U.S.A.
SERVICE PROCEDURES
After reviewing the instructions, if you feel the motor requires service (motor
may appear to have failed when other problems exist), obtain the most current
product service options & pricing by one of the following methods:
WEBSITE: Print a copy of the product SERVICE FORM from the SERVICE section of the
Novak website. Fill out the needed information & return it with the Novak product.
PHONE/FAX/E-MAIL: Contact our customer service department by phone, fax, or
e-mail, and they will supply you with current service options.
WARRANTY SERVICE: You MUST CLAIM WARRANTY on product SERVICE FORM & include
a valid, itemized cash register receipt with the purchase date on it, or an invoice from previ-
ous service work. If warranty provisions have been voided, there will be service charges.
ADDITIONAL NOTES:
• Dealers/distributors are not authorized to replace products thought to be defective.
• If a hobby dealer returns your product for service, submit a completed product SERVICE
FORM to dealer & make sure it’s included with 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, overheating
solder tabs, damage resulting from thermal overload or operation above 175°F, use of excessive timing or failure
from using non-Novak ESCs that advance motor timing, splices to sensor harness, damage from disassembling
motor, tampering with internal electronics, allowing water, moisture, or any other foreign material to enter
motor or get onto the PC board, short-circuiting of motor by allowing exposed wiring or solder tabs to to
cross-connect or ESC applying simultaneous power to more than one phase at a time from switching to Brush
Mode, free-revving motor, 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 & use of 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.
SERVICE PROCEDURES
After reviewing the instructions, if you feel the motor requires service (motor
may appear to have failed when other problems exist), obtain the most current
product service options & pricing by one of the following methods:
WEBSITE: Print a copy of the product SERVICE FORM from the SERVICE section of the
Novak website. Fill out the needed information & return it with the Novak product.
PHONE/FAX/E-MAIL: Contact our customer service department by phone, fax, or
e-mail, and they will supply you with current service options.
WARRANTY SERVICE: You MUST CLAIM WARRANTY on product SERVICE FORM & include
a valid, itemized cash register receipt with the purchase date on it, or an invoice from
previous service work. If warranty provisions have been voided, there will be service charges.
ADDITIONAL NOTES:
• Dealers/distributors are not authorized to replace products thought to be defective.
• If a hobby dealer returns your product for service, submit a completed product SERVICE
FORM to dealer & make sure it’s included with 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, overheating
solder tabs, damage resulting from thermal overload or operation above 175°F, use of excessive timing or
failure from using non-Novak ESCs that advance motor timing, splices to sensor harness, damage from disas-
sembling motor, tampering with internal electronics, allowing water, moisture, or any other foreign material
to enter motor or get onto the PC board, short-circuiting of motor by allowing exposed wiring or solder tabs
to to cross-connect or ESC applying simultaneous power to more than one phase at a time from switching to
Brush Mode, free-revving motor, 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 & use of 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, con-
sidered operational. By the act of connecting/operating speed control, the user accepts all resulting liability.
5mm Mod 1 Pinion Gears--9T to 16T--Hardened steel pinion gear for 550 (5mm) motors.
5109(9T); 5110(10T); 5100(11T); 5101(12T); 5102(13T);
5103(14T); 5104(15T); 5105(16T); 5111(17T); 5112(18T);
5113(19T); 5114(20T); 5116(21T); 5517(23T)
5mm 32 Pitch Pinion Gears--12T to 17T--Hardened steel pinion gear for 550 (5mm) motors.
5152 (12T); 5153 (13T); 5154 (14T); 5155 (15T); 5156 (16T); 5157 (17T)
1/8” Mod 0.6 Pinion Gear Sets--11T to 19T--Anodized aluminum 1/8” pinion gears.
5200 (11T/12T/13T); 5201 (14T/15T/16T); 5202 (17T/18T/19T)
5210 (11T/12T/13T); 5211 (14T/15T/16T); 5412 (17T/18T/19T)
5412 550 Brushless Motor Heat Sink--Large slide on heat sink for any 550-size motors.
S5414 540 Heat Sink Motor Sleeve--Purple--’V’ Logo/Replaces Novak 540 motor sleeve.
S5415 540 Heat Sink Motor Sleeve--Blue--’V’ Logo/Replaces Novak 540 motor sleeve.
S5417 540 Novak Brushless Motor Cooling Kit--Purple--Velociti heat sink & 25mm fan.
S5418 540 Novak Brushless Motor Cooling Kit--Blue--Velociti heat sink & 25mm fan.
S5420 540-Size Novak Brushless Motor Sleeve--Black--Novak 540 replacement sleeve.
S5421 540-Size Novak Brushless Motor Sleeve--Blue--Novak 540 replacement sleeve.
S5422 540-Size Novak Brushless Motor Sleeve--Gold--Novak 540 replacement sleeve.
S5423 540-Size Novak Brushless Motor Sleeve--Purple--Novak 540 replacement sleeve.
S5424 540-Size Novak Brushless Motor Sleeve--Orange--Novak 540 replacement sleeve.
S5425 550-Size Novak Brushless Motor Sleeve--Black--Novak 550 replacement sleeve.
5508 14GA Brushless Wire Set--2 pieces each of 9” silicone blue, yellow, orange, black, & red.
5509 16GA Brushless Wire Set--2 pieces each of 9” silicone blue, yellow, orange, black, & red.
5512 12GA Super-Flex Wire--Black, Red, & Blue--3 ft each color, silicone.
5514 14GA Super-Flex Wire--Black, Red, & Blue--3 ft each color, silicone.
5516 16GA Super-Flex Wire--Black, Red, & Blue--3 ft each color, silicone.
5647 Black Cooling Fan--25x25x10mm--All purpose cooling fan with 2-pin JST connector.
5648 Clear Cooling Fan--30x30x6mm--GTB replacement fan with 2-pin JST connector.
5721 2mm Power Connectors--5 pair--Gold plated low-loss connectors for 16-20G wire.
5731 3.5mm Power Connectors--5 pair--Gold plated low-loss connectors for 12-14G wire.
5741 4mm Power Connectors--5 pair--Gold plated low-loss high-amp 12-14G connectors.
5750 Novak Battery Connector Set--Polarized low-loss 2-wire connector for 12-14G wire.
S5812 Gold Battery Cross Bars--100pcs--Gold plated oxygen-free copper battery bars.
5831 Lead-Free 3% Silver Racing Solder--6g--Low-resistance, high-conductivity solder.
5832 Lead-Free 3% Silver Racing Solder--15g--Low-resistance, high-conductivity solder.
5833 Lead-Free 3% Silver Racing Solder--100g--Low-resistance, high-conductivity solder.
5840 Double-Sided Mounting Tape--10pcs--1”x1” high-performance clear mounting tape.
5841 Double-Sided Mounting Tape--10pcs--1”x1” high-performance clear mounting tape.
5850 Heat Shrink Tubing--6pcs--6” long tubing assortment in six sizes 1/16”-3/8”.
5851 Heat Shrink Tubing--24pcs--6” long tubing assortment in six sizes 1/16”-3/8”.
5909 Sintered Tuning Rotor--13mm high-power sintered neodymium tuning rotor.
5915 Three-80 Sintered Rotor--Three-80 motor replacement sintered neodymium rotor.
5916 Three-80 Front End Bell & Bearings--Replacement front end bell & both bearings.
5917 5mm Ribbed End Bell & Bearings--Replacement 5mm front end bell & bearings.
5919 Ribbed End Bell & Bearings-1/8”bore--Replacement front end bell & both bearings.
S5920 Smooth End Bell & Bearings-1/8”bore--Replacement front end bell & both bearings.
5935 Ceramic Ball Bearing ABEC-5--Replacement rear 1/8”I.D. ceramic bearing.
5936 Ceramic Ball Bearing ABEC-5--Replacement oversized, 3/16”I.D. front ceramic bearing.
5937 Steel Ball Bearings ABEC-3--Replacement rear 1/8”I.D. steel bearings.
5938 Steel Ball Bearings ABEC-5--Replacement oversized, 3/16”I.D. front steel bearings.
5939 Steel Ball Bearings ABEC-5--Replacement 5mm”I.D. front steel bearings for 550.
5941 Sintered 540 Rotor--12.3mm sintered neodymium replacement rotor.
5948 Sintered 550 Rotor--5mm--12.3mm sintered neodymium replacement rotor.
5mm Mod 1 Pinion Gears--9T to 16T--Hardened steel pinion gear for 550 (5mm) motors.
5109(9T); 5110(10T); 5100(11T); 5101(12T); 5102(13T);
5103(14T); 5104(15T); 5105(16T); 5111(17T); 5112(18T);
5113(19T); 5114(20T); 5116(21T); 5517(23T)
5mm 32 Pitch Pinion Gears--12T to 17T--Hardened steel pinion gear for 550 (5mm) motors.
5152 (12T); 5153 (13T); 5154 (14T); 5155 (15T); 5156 (16T); 5157 (17T)
1/8” Mod 0.6 Pinion Gear Sets--11T to 19T--Anodized aluminum 1/8” pinion gears.
5200 (11T/12T/13T); 5201 (14T/15T/16T); 5202 (17T/18T/19T)
5210 (11T/12T/13T); 5211 (14T/15T/16T); 5412 (17T/18T/19T)
5412 550 Brushless Motor Heat Sink--Large slide on heat sink for any 550-size motors.
S5414 540 Heat Sink Motor Sleeve--Purple--’V’ Logo/Replaces Novak 540 motor sleeve.
S5415 540 Heat Sink Motor Sleeve--Blue--’V’ Logo/Replaces Novak 540 motor sleeve.
S5417 540 Novak Brushless Motor Cooling Kit--Purple--Velociti heat sink & 25mm fan.
S5418 540 Novak Brushless Motor Cooling Kit--Blue--Velociti heat sink & 25mm fan.
S5420 540-Size Novak Brushless Motor Sleeve--Black--Novak 540 replacement sleeve.
S5421 540-Size Novak Brushless Motor Sleeve--Blue--Novak 540 replacement sleeve.
S5422 540-Size Novak Brushless Motor Sleeve--Gold--Novak 540 replacement sleeve.
S5423 540-Size Novak Brushless Motor Sleeve--Purple--Novak 540 replacement sleeve.
S5424 540-Size Novak Brushless Motor Sleeve--Orange--Novak 540 replacement sleeve.
S5425 550-Size Novak Brushless Motor Sleeve--Black--Novak 550 replacement sleeve.
5508 14GA Brushless Wire Set--2 pieces each of 9” silicone blue, yellow, orange, black, & red.
5509 16GA Brushless Wire Set--2 pieces each of 9” silicone blue, yellow, orange, black, & red.
5512 12GA Super-Flex Wire--Black, Red, & Blue--3 ft each color, silicone.
5514 14GA Super-Flex Wire--Black, Red, & Blue--3 ft each color, silicone.
5516 16GA Super-Flex Wire--Black, Red, & Blue--3 ft each color, silicone.
5647 Black Cooling Fan--25x25x10mm--All purpose cooling fan with 2-pin JST connector.
5648 Clear Cooling Fan--30x30x6mm--GTB replacement fan with 2-pin JST connector.
5721 2mm Power Connectors--5 pair--Gold plated low-loss connectors for 16-20G wire.
5731 3.5mm Power Connectors--5 pair--Gold plated low-loss connectors for 12-14G wire.
5741 4mm Power Connectors--5 pair--Gold plated low-loss high-amp 12-14G connectors.
5750 Novak Battery Connector Set--Polarized low-loss 2-wire connector for 12-14G wire.
S5812 Gold Battery Cross Bars--100pcs--Gold plated oxygen-free copper battery bars.
5831 Lead-Free 3% Silver Racing Solder--6g--Low-resistance, high-conductivity solder.
5832 Lead-Free 3% Silver Racing Solder--15g--Low-resistance, high-conductivity solder.
5833 Lead-Free 3% Silver Racing Solder--100g--Low-resistance, high-conductivity solder.
5840 Double-Sided Mounting Tape--10pcs--1”x1” high-performance clear mounting tape.
5841 Double-Sided Mounting Tape--10pcs--1”x1” high-performance clear mounting tape.
5850 Heat Shrink Tubing--6pcs--6” long tubing assortment in six sizes 1/16”-3/8”.
5851 Heat Shrink Tubing--24pcs--6” long tubing assortment in six sizes 1/16”-3/8”.
5909 Sintered Tuning Rotor--13mm high-power sintered neodymium tuning rotor.
5915 Three-80 Sintered Rotor--Three-80 motor replacement sintered neodymium rotor.
5916 Three-80 Front End Bell & Bearings--Replacement front end bell & both bearings.
5917 5mm Ribbed End Bell & Bearings--Replacement 5mm front end bell & bearings.
5919 Ribbed End Bell & Bearings-1/8”bore--Replacement front end bell & both bearings.
S5920 Smooth End Bell & Bearings-1/8”bore--Replacement front end bell & both bearings.
5935 Ceramic Ball Bearing ABEC-5--Replacement rear 1/8”I.D. ceramic bearing.
5936 Ceramic Ball Bearing ABEC-5--Replacement oversized, 3/16”I.D. front ceramic bearing.
5937 Steel Ball Bearings ABEC-3--Replacement rear 1/8”I.D. steel bearings.
5938 Steel Ball Bearings ABEC-5--Replacement oversized, 3/16”I.D. front steel bearings.
5939 Steel Ball Bearings ABEC-5--Replacement 5mm”I.D. front steel bearings for 550.
5941 Sintered 540 Rotor--12.3mm sintered neodymium replacement rotor.
5948 Sintered 550 Rotor--5mm--12.3mm sintered neodymium replacement rotor.
ACCESSORIES ACCESSORIES
BRUSHLESS MOTOR
INSTRUCTIONS
55-3400-1 Rev.9
BRUSHLESS MOTOR
INSTRUCTIONS
55-3400-1 Rev.9