Novak Important HV Maxx Gearing Update (55-3221-1) - Manual

#55-3221-1
6-2008
SPECIFICATIONS
Input Voltage--NiMH .............................6-14 cells (1.2 volts DC/cell)
Input Voltage--LiPo ............................................ 2-4 cells (2S to 4S)
ESC Footprint .................................... 1.75” x 2.17” [44.5 x 55.1mm]
ESC Weight (w/o wires) ................................ 4.76 ounce [135 grams]
On-Resistance (Transistors @ 25°C) ................................. 0.0013 x 2 Ω
Rated Current (Transistors @ 25°C) ......................400 amps [per phase]
Power Wire (battery/motor) ........................ 14G Super-Flex Silicone
B.E.C. Voltage ............................................................6.0 volts DC
B.E.C. Current ................................................................3.0 amps
Motor Limit ...................Any Novak Sensor-Based 550-size Brushless
Motor Commutation ................................Sensor-Based Electronic
LiPo Cut-Off Voltage
(automatic) ....... 6.25V (2S) , 9.375 (3S) , 12.5V (4S)
Throttle Profiles ........................................ 3 (2 w/Reverse & 1 without)
High-voltage/high-power brushless plus complete programmability!
The HV Pro brushless system is the perfect high-power reversible electronic speed control & sensor-based brushless motor upgrade for big trucks, hot
boats, & other high-power R/C applications where you want all the benefits of brushless motors plus smoother throttle response & the best efficiency!
The HV Pro features full programmability, built-in LiPo Cut-Off Circuitry, & Novak’s Smart Braking II (you don’t go into reverse until you shift into reverse by returning the trigger to neutral & then back
to reverse), Thermal Overload Protection, high-power B.E.C. for strong/fast servo response, Polar Drive & Digital Anti-Glitch circuitries for cool & smooth operation, & 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, and the HV Pro is ready for anything!
• To benefit from all of the HV Pro’s extensive technical features, PLEASE READ ALL INSTRUCTIONS CAREFULLY •
WATER & ELECTRONICS DON’T MIX!
Never expose ESC to water, moisture, or other foreign materials. Water damage voids the warranty!
DISCONNECT BATTERIES WHEN NOT IN USE
Disconnect battery packs from ESC when not in use to avoid short circuits & possible fire hazard.
6 TO 14 CELLS OR 2-4 CELL LiPo ONLY
NiMH-- NEVER use fewer than 6 or more than 14 cells (1.2V/cell) & be sure LiPo Cut-Off is turned OFF.
LiPo--Use dual 2-cell (2S) packs for main battery & be sure the LiPo Cut-Off option is turned ON.
NOVAK MOTORS ONLY
The HV Pro ESC is specially designed for use with sensor-based Novak HV-Series 550-size Brushless
Motors Only! Motors must have thermal protection. 540-size motors should not be used. Check
Novak Web site for motor compatibility list.
NEVER FREE-REV THE MOTOR!!!
Free-running your brushless motor in a no-load condition can result in rotor failure and speed
control transistor damage & will void the product’s warranty!
NO REVERSE VOLTAGE!
Reverse battery polarity can damage ESC & void warranty. Disconnect battery immediately.
ALWAYS USE ESC HEAT SINKS & FAN
ESC heat sinks MUST be used (and included fan should be used) for optimum cooling. Allowing
individual heat sinks to touch each other or any conductive surface will short circuit & damage ESC.
POWER CAPACITOR REQUIRED
The HV Pro’s factory-installed external Power Trans-Cap Module MUST be used.
Failure to use PowerCap Module will result in higher ESC temperatures & thermal shut-down.
TRANSMITTER POWER ON FIRST
Always turn on transmitter power first so you will have control of the vehicle when you turn it on.
GOOD QUALITY TRANSMITTER SUGGESTED
With the higher performance of brushless systems, undesirable radio system noise may occur
when used with lower quality transmitters (like some RTR radios).
DO NOT BUNDLE POWER & SIGNAL WIRES TOGETHER
RF noise in the power wires can adversely effect radio system performance.
INSULATE EXPOSED WIRES
Use heat shrink tubing or electrical tape to insulate exposed wiring & prevent short circuits.
NO CA GLUE ON ESC
CA glue & its fumes can damage internal ESC components and result in premature failure.
With ESC connected to (at least) a receiver & fully-charged batteries:
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 ESC is at neutral, and
proper programming has been completed
(blue & amber LEDs may also be on)
.
Your HV 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.
The HV Pro ESC has 3 built-in throttle profiles (2 w/reverse & 1 without)
plus complete programmability of several ESC parameters to let you
fine-tune the speed control just the way you want it.
See the included Custom Programming & Gearing sheet for more details.
trouble-shooting guide
Motor Does Not Operate and ESC LEDs Are Scrolling
• Motor may not have temperature protection––ESC will not operate without Thermal Overload
Protection. Check Novak Web site for the complete motor compatibility test.
• Blue sensor harness may be disconnected––Check connection.
Steering Channel Works But Motor Will Not Run
• LiPo Cut-Off Circuitry activated––Disconnect LiPo battery pack and re-charge.
• LiPo Cut-Off Circuitry is active & you are using NiMH batteries. Circuitry will cut throttle
output very early into the run if you are using NiMH cells––Turn off LiPo Cut-Off.
• All status LEDs scroll from left to right––Check blue sensor harness wire for disconnection
or motor does not have temperature protection. For proper operation, replace blue sensor
harness wire or motor with temperature protection.
• Red status LED blinking when throttle is applied. Check motor sensor harness connection at ESC
(all metal sockets must be 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.
• Green & red status LEDs blinking. LiPo Cut-Off Circuitry’s safety cut-off voltage has been reached
--replace battery pack with a fully charged one.
• Blue & green status LEDs both blinking. Possible ESC shut-down due to locked rotor detection
––return throttle to neutral 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 Trans-Cap Module.
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.
Model Runs Slowly/Slow Acceleration
• Gear ratio too high––Reduce gear ratio.
• Check battery connectors––Replace if needed.
• Incorrect transmitter/ESC adjustment––Refer to ‘TRANSMITTER ADJUSTMENTS’.
• External Power Capacitor damaged/not installed––Replace Power Trans-Cap Module.
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 Web site.
service procedures
Before sending in your speed control or brushless motor system for service,
review Trouble-Shooting guide and instructions. System may appear to have
failed when other problems exist.
After reviewing instructions, if you feel that your ESC/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..
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/motors 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.
PRECAuTIONS optional accessories
P1 P4
step
5
–
one-touch programming
If you have any problems with Step 5, adjust transmitter as follows,
and then repeat the One-Touch programming in Step 5:
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•
transmitter adjustments
using a receiver battery pack
If using an external receiver battery pack with the HV Pro ESC:
1. Plug an external 5 cell (1.2VDC/cell) receiver battery pack into
the battery slot of the receiver.
2. Leave the HV Pro’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 must be used
when using the HV Pro with a single 12 volt battery, like a lead acid or
gel cell. The ESC’s built-in B.E.C. will not provide enough output due to
the high voltage directed through the single battery input, resulting in
degraded servo/receiver performance and B.E.C. over-heating & failure.
HV PRO BASIC SET-UP GUIDE
• See ‘Programming & Gearing’ sheet for Proper Gearing, Profile Selection, Custom Programming, & LiPo Cut-Off •
product warranty
The HV Pro ESC is 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 to case or exposed circuit boards, damage from using fewer than 6 or more than 14 cells (1.2
volts DC/cell) or more than 4 LiPo cells (4S) input voltage, cross-connection of battery/motor power wires, overheating
solder tabs, reverse voltage application, damage resulting from thermal overload, short-circuiting or free-revving 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, using 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, 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 natural disaster.
Because Novak Electronics has no control over the connection & use of the speed control or other related elec-
tronics, 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. Designed by Novak Electronics, Inc. in Irvine, CA and assembled with globally sourced components.
©2008 Novak Electronics, Inc. • All Rights Reserved • No part of these instructions may be reproduced without
the written permission of Novak Electronics, Inc. • HV Pro ESC, Smart Braking II, Polar Drive Technology, Radio
Priority Circuitry, & One-Touch Set-Up are all trademarks of Novak Electronics, Inc.
5100 5mm Mod 1 Pinion Gear--Hardened steel pinion gear for 5mm shaft motors (11T).
5101 5mm Mod 1 Pinion Gear--Hardened steel pinion gear for 5mm shaft motors (12T).
5102 5mm Mod 1 Pinion Gear--Hardened steel pinion gear for 5mm shaft motors (13T).
5103 5mm Mod 1 Pinion Gear--Hardened steel pinion gear for 5mm shaft motors (14T).
5104 5mm Mod 1 Pinion Gear--Hardened steel pinion gear for 5mm shaft motors (15T).
5105 5mm Mod 1 Pinion Gear--Hardened steel pinion gear for 5mm shaft motors (16T).
5109 5mm Mod 1 Pinion Gear--Hardened steel pinion gear for 5mm shaft motors (9T).
5110 5mm Mod 1 Pinion Gear--Hardened steel pinion gear for 5mm shaft motors (10T).
5152 5mm 32 Pitch Pinion Gear--Nickel plated steel pinion gear for 5mm shaft motors (12T).
5153 5mm 32 Pitch Pinion Gear--Nickel plated steel pinion gear for 5mm shaft motors (13T).
5154 5mm 32 Pitch Pinion Gear--Nickel plated steel pinion gear for 5mm shaft motors (14T).
5155 5mm 32 Pitch Pinion Gear--Nickel plated steel pinion gear for 5mm shaft motors (15T).
5156 5mm 32 Pitch Pinion Gear--Nickel plated steel pinion gear for 5mm shaft motors (16T).
5157 5mm 32 Pitch Pinion Gear--Nickel plated steel pinion gear for 5mm shaft motors (17T).
5315 User-Replaceable Input Signal Harness--4.5”--Replacement plug-in input signal harness.
5315 User-Replaceable Input Signal Harness--9”--Replacement plug-in input signal harness.
5412 HV Brushless Motor Heat Sink--Replacement slide-on heat sink for 550-size motor.
5463 3-Amp High-Voltage Universal BEC--Universal external high-voltage B.E.C. module.
5508 14GA Brushless Wire Set--2 pieces each of 9” silicone blue, yellow, orange, black, & red.
5512 12GA Silicone Power Wire Set--3’ each of black, red, & blue silicone Super-Flex wire.
5514 14GA Silicone Power Wire Set--3’ each of black, red, & blue silicone Super-Flex wire.
5600 ESC Switch Harness--Replacement ON/OFF switch harness for speed controls.
5611 Dual Cooling Fan Y-Harness--Harness for connecting 2 cooling fans to Novak ESCs.
5644 Cooling Fan--40x40x10mm black--Cooling fan with 2-pin JST connector. Fits HV ESC.
5645 Power-Boost ESC Cooling Fan Kit--40x40x10mm black cooling fan with mounting bracket.
5684 Power Trans-Cap Module--2700µF/25V--Replacement HV power capacitor module.
5730 3.5mm Power Connectors--2 pair--Gold plated low-loss 12-14G power connectors.
5731 3.5mm Power Connectors--5 pair--Gold plated low-loss 12-14G power connectors.
5732 3.5mm Power Connectors--12 male--Gold plated low-loss 12-14G power connectors.
5733 3.5mm Power Connectors--12 female--Gold plated low-loss 12-14G power connectors.
5740 4mm Hi-Amp Connectors--2 pair--Gold plated low-loss 12-14G heavy duty connectors.
5741 4mm Hi-Amp Connectors--5 pair--Gold plated low-loss 12-14G heavy duty connectors.
5742 4mm Hi-Amp Connectors--12 male--Gold plated low-loss 12-14G heavy duty connectors.
5743 4mm Hi-Amp Connectors--12 female--Gold plated low-loss 12-14G heavy duty connectors.
5810 Gold Battery Cross Bars--7pcs--Gold plated oxygen-free copper battery bars.
5811 Gold Battery Cross Bars--28pcs--Gold plated oxygen-free copper battery bars.
5820 Silver Battery Cross Bars--7pcs--Oxygen-free copper battery bars. Plated for easy soldering.
5821 Silver Battery Cross Bars--28pcs--Oxygen-free copper battery bars. Plated for easy soldering.
5831 Lead-Free 3% Silver Solder--6g--Low-resistance, high-conductivity solder.
5832 Lead-Free 3% Silver Solder--15g--Low-resistance, high-conductivity solder.
5833 Lead-Free 3% Silver 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--100pcs--1”x1” high-performance clear mounting tape.
5912 HV Sintered Rotor--1/8”--Sintered neodymium rotor for 1/8” shaft HV-series motors.
5914 HV Sintered Rotor--5mm--Sintered neodymium rotor for 5mm shaft HV-series motors.
5917 Ribbed End Bell & Bearings--5mm--Front end bell & bearings for 5mm shaft HV motors.
5919 Ribbed End Bell & Bearings--1/8”--Front end bell & bearings for 1/8” shaft HV motors.
5931 550-Size Motor Hardware Kit--Replacement shims & screws for 550-size Novak motors.
Novak Electronics, Inc.
17032 Armstrong Avenue
Irvine, CA 92614
(949) 833-8873 • FAX (949) 833-1631
Customer Service e-mail: [email protected]
Monday-Friday: 8:00am-5:00pm (PST)
w w w . t e a m n o v a k . c o m