Novak HV Motor Wiring & Gear Selection (55-3020-1) - Manual

#55-3020-1
12-2004
SPECIFICATIONS
Input Voltage ........................................ 6-14 cells (1.2 volts DC/cell)
ESC Case Size ...................... 1.75”x2.17”x0.85” [44.5x55.1x21.6mm]
ESC Weight (w/o wires) ..................................... 4.80 ounce [135 grams]
On-Resistance @ Transistors/25
°
C ....................................... 0.0013 x 2
Ω
ESC Power Handling (Transistors @ 25
°
C) .................................. 375 watts
ESC Power Handling (Transistors @ 25
°
C) ........... 525 watts [w/cooling fan]
B.E.C. Voltage/Current ............................... 6.0 volts DC/3.0 amps
Power Wire .............................................. 14G Super-Flex Silicone
ESC Throttle Programs ............. 3
[2 w/Reverse & 1 Forward & Brake only]
HV Motor Diameter .............................................. 1.41” [35.8mm]
HV Motor Length ................................................. 2.84” [72.1mm]
HV Motor Weight (w/o heat sink) ...................... 8.4 ounce [295 grams]
Motor Commutation ............................... Sensor-Based Electronic
Motor Magnet Material .................. Neodymium
[1piece/multi-pole]
The ultimate high-voltage/high-power brushless is here & it is the HV-Maxx!
The HV-Maxx brushless motor system is the best high-power reversible electronic speed control & sensor-based brushless
motor upgrade that you can throw at your big trucks, hot boats, or any other high-power R/C application where you want all
the benefits of brushless motors & it’s even smoother, more controlled, and more driveable than standard brush-type systems!
With 3 factory throttle programs to choose from & Novak’s Smart Braking II (you don’t go into reverse until you shift into reverse by returning the trigger to
neutral and then back to reverse), the HV-Maxx is perfect for any high-power application. The HV-Maxx system has Thermal Overload Protection in both the
motor & ESC, high-power B.E.C. for strong/fast servo response, Polar Drive & Digital Anti-Glitch circuitries for cool & smooth operation, and Radio Priority
circuitry for the ultimate in control, right down to the end of the battery. Add to this the included Power-Boost ESC Cooling Fan kit & factory-installed
motor heat sink, the user-replaceable battery wires, power capacitor, ON/OFF switch, & input harness, and the HV-Maxx is ready for anything!
To benefit from all of the HV-Maxx’s extensive technical features, PLEASE READ ALL INSTRUCTIONS
POWER-BOOST ESC COOLING FAN KIT [Novak kit #5646]
Direct-replacement for the cooling fan kit that is included in the HV-Maxx high-voltage
brushless system. Everything needed to pull maximum power from the HV-Maxx
ESC for hot set-ups: custom-fit fan bracket, mounting screws, & high-volume
cooling fan that plugs into HV-Maxx ESC’s fan power output jack.
SUPER-FLEX SILICONE POWER WIRE [Novak kits #5500 & 5530]
Novak Super-Flex wire for power wiring. 14 guage silicone wire in kit #5500
(36”red & 36”black), and 12G silicone in kit #5530 (36”red & 36”black).
INPUT SIGNAL HARNESS [Novak kits #5315 & 5320]
User-replaceable input signal harnesses are available for the HV-Maxx in
both short/4.5” (#5315) and long/9” lengths (#5320).
REPLACEMENT SWITCH HARNESS [Novak kit #5600]
The replacement switch harness has ON/OFF switch with pre-tinned wires
ready to solder to the HV-Maxx ESC’s Direct-Solder Wire Tabs.
H-SERIES MOTOR END BELL & BEARING SET
After extensive use, the ball bearings in the end bells of your brushless mo-
tor may need to be replaced. Replacement front end bell with oversize bearing
installed & rear bearing are available in Novak kit #5910.
WATER & ELECTRONICS DON’T MIX!
Never allow water, moisture, or other foreign materials to get inside
ESC, motor, or on the PC Boards. Water damage will void the warranty!
CHECK MOTOR SCREWS!
Check M3 motor mounting screw length–– too long of mounting screws
will damage motor & void warranty. The main 4-40 socket head & end
cap’s flat head screws may also loosen after a few runs––tighten if needed.
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.
6 TO 14 CELLS ONLY
Never use fewer than 6 or more than 14 cells (7.2-16.8VDC, 1.2VDC/
cell) in the vehicle’s main battery pack(s).
NOVAK MOTORS ONLY
The HV-Maxx ESC is specially designed for use with sensor-based
Novak HV-Series Brushless Motors Only! You may replace motor with
Novak sensored motor rated up to 375W (ESC’s rating)––Novak SS-Series
(540 size) motors will work, but will run hot and thermally shutdown.
At the time of printing, there are no other motor’s available that work with
the HV-Maxx ESC––check our website for further updates & compatibilities.
NO REVERSE VOLTAGE!
Reverse battery polarity can damage ESC & void warranty. Disconnect
battery immediately if a reverse connection occurs.
ALWAYS USE ESC HEAT SINKS
Heat sinks are factory-installed on your HV-Maxx ESC and MUST be
used for maximum cooling and performance––Never allow separate
heat sinks to touch each other or any exposed metal or conductive
surface, as this will cause a short circuit & damage ESC.
POWER CAPACITOR REQUIRED
An external power capacitor is installed and MUST be used with your
HV-Maxx ESC. Failure to use Power Capacitor will result in higher ESC
operating temperatures & possible thermal shut-down.
TRANSMITTER ON FIRST
Always turn on the power of the transmitter first so that you will have
control of the vehicle when you turn it on.
INSULATE WIRES
Always insulate exposed wiring with heat shrink tubing or electrical
tape to prevent short circuits, which can damage ESC.
NO CA GLUE
Exposure to CA glue or its fumes can cause damage to internal
components of the speed control and result in premature failure.
With ESC connected to (at least) a receiver & a charged battery pack:
1. TURN ON THE TRANSMITTER’S POWER
2. PRESS & HOLD ESC’S ONE-TOUCH/SET BUTTON
3. TURN ON THE SPEED CONTROL’S POWER
With transmitter throttle at neutral, and still pressing the SET button,
slide the ESC’s ON/OFF switch to ON position.
4. CONTINUE HOLDING SET BUTTON UNTIL RED LED COMES 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 throttle is at neutral,
and proper programming has been completed.
Your HV-Maxx Brushless System is now Ready-To-Run!
NOTE: If transmitter settings are changed, programming must be repeated. If
you experience any problems, turn off ESC and repeat programming.
trouble-shooting guide trouble-shooting guide
Steering Channel Works But Motor Will Not Run
• Red status LED blinking when throttle is applied. Check motor sensor harness
connection at ESC (make sure all metal sockets are fully inserted into the connector’s
plastic housing)––check for damaged wires.
• Green & red status LEDs both on solid. Check input signal harness is plugged into
ESC & receiver throttle channel. Check throttle channel operation with a servo.
Check receiver signal harness wiring sequence.
• Blue & green status LEDs both blinking. Possible ESC 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 & Red status LEDs blinking. Possible ESC thermal shut-down––Check gear ratio
& free operation of drive train for possible overloading/ESC is being severely over-
loaded––allow system to cool & return throttle to neutral position to regain motor
control. LEDs will continue to blink until system is cooled down.
• Blue & Amber status LEDs blinking. Possible motor thermal shut-down––Check gear
ratio & free operation of drive train for possible overloading/motor is being over-
loaded––allow system to cool & return throttle to neutral position to regain motor
control. LEDs will continue to blink until system is cooled down.
• Blue & green (Locked Rotor Detection), Blue & Red (ESC Thermal Shut-Down), or
Blue & Amber (Motor Thermal Shut-Down) status LEDs blinking. ESC may have shut-
down due to thermal overload or locked rotor detection & ESC’s neutral point is
too far off to sense throttle has been returned to neutral––Refer to Steps 5 & 6.
• Possible internal damage––Refer to Service Procedures.
Receiver Glitches/Throttle Stutters During Acceleration
• Receiver or antenna too close to ESC, power wires, battery, or motor.
• Bad connections––Check wiring, connectors, & sensor harness.
• External Power Capacitor damaged/not installed––Replace Power Capacitor.
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 Excessively Hot
• Gear ratio too low––Increase gear ratio (see ‘GEAR SELECTION’).
Model Runs Slowly/Slow Acceleration
• Gear ratio too high––Reduce gear ratio (see ‘GEAR SELECTION’).
• Check battery connectors––Replace if needed.
• Incorrect transmitter/ESC adjustment––Refer to Steps 5 & 6.
• External Power Capacitor damaged/not installed––Replace Power Capacitor.
ESC Is Melted Or Burnt/ESC Runs With Switch Off
• Internal damage––Refer to Service Procedures.
*For more assistance call our Customer Service Department or check our website.
service procedures service procedures
Before sending your system in for ser vice, review Trouble-Shooting guide and
instructions. System may appear to have failed when other problems exist.
After reviewing instructions, if you feel your system requires service, please obtain
the most current product service options & pricing by the following:
WEBSITE:
Print a copy of the PRODUCT SERVICE FORM from the CUSTOMER SERVICE
section of the website. Fill out the needed information on this form and return it with
the Novak product that requires servicing.
PHONE/FAX: If you do not have access to the internet, please contact our customer
service deptartment by phone or fax as listed below.
WARRANTY SERVICE: For warranty work, you MUST CLAIM WARRANTY on
PRODUCT SERVICE FORM & include a valid cash register receipt with purchase date
and dealer name & phone# on it, or an invoice from previous service. If warranty
provisions have been voided, there will be service charges.
•ESCs returned without a serial number will not be serviced under warranty•
ADDITIONAL NOTES:
• Dealers/distributors are not authorized to replace Novak products thought to be defective.
• If a hobby dealer returns your brushless system for service, submit a completed
PRODUCT SERVICE FORM to the dealer and make sure it is included with the product.
• Novak Electronics, Inc. does not make any internal electronic components (transistors,
resistors, etc.) available for sale.
Novak Electronics, Inc.
(949) 833-8873 • FAX (949) 833-1631
Customer Service e-mail: [email protected]
Monday-Thursday: 8:00am-5:00pm (PST)
Friday: 8:00am-4:00pm (closed every other Friday)
w w w . t e a m n o v a k . c o m
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PRECAuTIONS optional accessories
P1 P4
step step step step step
6 6 6 6 6
–
one-touch programming
The HV-Maxx ESC has 3 user-selectable Throttle Programs to choose from:
PROGRAM #1: Forward, brakes, and full power reverse.
PROGRAM #2: Forward & brakes only--reverse disabled.
PROGRAM #3: Forward, brakes, and 25% power reverse.
selecting throttle progra selecting throttle program m
::
With ESC connected to a charged battery (transmitter ON or OFF):
1. IF TRANSMITTER IS OFF, DISCONNECT ESC FROM RECEIVER
To avoid possible radio interference from other transmitters, remove
the HV-Maxx’s input signal harness from the receiver.
2. TURN ON THE SPEED CONTROL’S POWER
3. PRESS & HOLD THE ONE-TOUCH SET BUTTON
Continue to hold SET button on ESC until all the LEDs turns on.
4. RELEASE SET BUTTON AS SOON AS ALL LEDs COME ON
Once released, the status LEDs will flash to indicate what Throttle
Program is currently selected. The number of times the LEDs flash
indicates the Throttle Program selection (1 of 3).
5. QUICK PRESS (& release) SET BUTTON TO CHANGE SELECTION
Each press will change to the next consecutive Throttle Program.
(After Program 3, the sequence begins again at Program 1)
Note: there is a time constraint during this selection process.
If SET button is not pressed for about 3 seconds, ESC will exit to neutral.
6. ESC STORES SELECTION & EXITS TO NEUTRAL
When SET button is not pressed for about 3 seconds, the selected
Program is stored into memory & the red LED will come on solid.
The speed control is at neutral & ready to go.
NOTE: Whenever the One-Touch set-up is performed, the HV-Maxx ESC will
automatically revert to the factory default setting of Throttle Program #1.
throttle program selection
For proper ESC operation, adjust transmitter as follows:
A. Set HIGH ATV or EPA to maximum setting.
[amount of throw at full throttle]
B. Set LOW ATV, EPA, or ATL to maximum setting.
[amount of throw at full brakes]
C. Set EXPONENTIAL to zero setting. [throttle channel linearity]
D. Set THROTTLE CHANNEL REV. SWITCH to either position.
E. Set THROTTLE CHANNEL TRIM to middle setting.
[adjusts neutral position/increases or decreases coast brakes]
F. Set ELECTRONIC TRIGGER THROW ADJUSTMENT to 50%
throttle and 50% brake throw (or 5:5).
[adjusts trigger throw electronic/digital pistol-grip transmitters]
G. Set MECHANICAL TRIGGER THROW ADJUSTMENT to position
with 1/2 throttle and 1/2 brake throw.
[adjusts trigger throw on mechanical/analog pistol-grip transmitters]
•NOT ALL TRANSMITTERS HA
VE THESE ADJUSTMENTS•
step step step step step
5 5 5 5 5
–
transmitter adjustments using a receiver battery pack using a receiver battery pack using a receiver battery pack using a receiver battery pack using a receiver battery pack
If using an external receiver battery pack with the HV-Maxx ESC:
1. Plug an external 5 cell (1.2VDC/cell) receiver battery pack into
the battery slot of the receiver.
2. Leave the HV-Maxx’s ON/OFF switch in the OFF position, and
use receiver battery pack’s ON/OFF switch to turn the system
power on and off––Do not use the ESC’s switch.
12VDC BATTERY NOTE: An external receiver battery pack should be used
when using the HV-Maxx with a single 12 volt battery, like a lead acid or
gel cell. The ESC’s built-in B.E.C. will provide limited output due to the
high voltage directed through the single battery input, resulting in
degraded servo and receiver performance.
product warranty product warranty
The HV-Maxx brushless motor system is guaranteed to be free from defects in materials or workmanship for a
period of 120 days from the original date of pur chase (verified by dated, itemized sales receipt). Warranty does not
cover incorrect installation, components worn by use, damage to case or exposed ciruit boards, damage from
using fewer than 6 or more than 14 cells (1.2 volts DC/cell) input voltage, cross-connection of batter y/motor
power wires, overheating solder tabs, reverse voltage application, damage resulting from thermal overload or
short-circuiting motor, damage from incorrect installation of FET servo or receiver battery pack, not using or
incorrect installation of a Power Capacitor on the ESC or from using a damaged Power Capacitor, using a
Schottky diode or non-Novak Power Capacitor or motor, splices to input, ON/OFF switch, or sensor harnesses,
damage from excessive force when using the One-Touch/SET button or from disassembling case or motor or
using too long of motor mounting screws, tampering 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.
Because Novak Electronics, Inc. has no control over the connection & use of the speed control or other related
electronics, no liability may be assumed nor will be accepted for any damage resulting from the use of this
product. Every Novak speed control & motor is thoroughly tested & cycled before leaving our facility and is,
therefore, considered operational. By the act of connecting/operating speed control, user accepts all resulting
liability. In no case shall our liability exceed the product's original cost. We reserve the right to modify warranty
provisions without notice.
©2004 Novak Electronics, Inc. • All Rights Reserved • No part of these instructions may be reproduced with-
out the written permission of Novak Electronics, Inc. • Super Duty XR ESC, Smart Braking II, Polar Drive
Technology, Radio Priority Circuitry, & One-Touch Set-Up are all trademarks of Novak Electronics, Inc. • All
Novak speed controls & motors are designed & manufactured in the U.S.A.