Novak Super Sport Brushless Motor System (SS5800 & SS4300 Motors) (3005) - Manual (Page 2)

If you experienced any problems while performing the
One-Touch programming in Step 5, use the following
procedure to check that your transmitter has adequate throw.
With transmitter ON, ESC OFF & connected to receiver & battery:
1. PRESS & HOLD SPEED CONTROL’S SET BUTTON
2. TURN ON SPEED CONTROL’S POWER
(while holding SET button)
3. HOLD SET BUTTON UNTIL BLUE, AMBER, & RED LEDs ON
4. RELEASE SPEED CONTROL’S SET BUTTON
Once blue, amber, & red LEDs (left 2 LEDs + right LED) turn on,
release the Super Sport’s SET button. Red LED will stay on.
5. PULL TRANSMITTER THROTTLE IN DRIVE DIRECTION
Slowly pull throttle toward full drive––blue LED blinks until 500 µ S of
throw is reached when it turns solid. (refer to Step 4/A to adjust throw)
6. PUSH TRANSMITTER THROTTLE IN BRAKE DIRECTION
Slowly push throttle toward full brake––amber LED blinks until 200 µ S of
throw is reached when it turns solid. (refer to Step 4/B to adjust throw)
Note: Without transmitter adjustments mentioned in Step 4/A & 4/B, ESC
will still program & operate normally with a minimum of
±
90
µ
S of throw.
The Super Sport is equipped with 6 user-selectable Throttle
Programs to choose from, as shown in the chart below.
THROTTLE PROGRAMS
SS STANDARD SS HIGH SPORTSMAN
1 2 3 4 5 6
RPM** unlim. unlim. unlim. umlim. 24000 24000
Acceleration* unlim. unlim. unlim. unlim. fixed fixed
Min.Brake low low high high low low
w/Reverse yes no yes no yes no
**Unlimited RPM is based upon motor’s rating. 5800Kv motor produces
41760 RPM @ 7.2 volts DC.
*Unlimited acceleration refers to acceleration only being limited by the
quality of the batteries used. Fixed acceleration is accomplished by only
allowing a factory programmed acceleration rate--all Super Sport ESCs
are programmed with the same fixed acceleration rate for programs 5 & 6.
Selecting Throttle Program--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 transmitter throttle at neutral, press and hold SET
button on Super Sport until all 4 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 Program selected.
4. PRESS & RELEASE SET BUTTON TO SELECT PROGRAM
Each press will change to the next consecutive Program
number.
(After Program #6, the sequence begins again at Program #1)
5. WAIT FOR SPEED CONTROL TO EXIT PROGRAMMING
When SET button is not pressed for about 3 seconds, the
ESC loads the selected Program into memory and exits
programming--red status LED will turn solid red indicating
that the speed control is at neutral and ready to go.
Selecting Throttle Program--WITHOUT TRANSMITTER
With the transmitter power OFF (or input harness disconnected) :
1. TURN ON THE SPEED CONTROL’S POWER
When speed control is powered on and no input signal
is being received from the receiver, the green and red
status LEDs will both turn on solid. This acts as a system
check at all times to let you know the condition of the
connection between your receiver and the Super Sport ESC.
2. PRESS & HOLD SPEED CONTROL’S SET BUTTON
Press and hold SET button on ESC until all 4 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 Program selected.
4. PRESS & RELEASE SET BUTTON TO SELECT PROGRAM
Each press will change to the next consecutive Program.
5. WAIT FOR SPEED CONTROL TO EXIT PROGRAMMING
SET button not pressed for 3 sec.--ESC exits programming.
STEP 8 STEP 6
OPTIONAL SET-UP
CHECKING TRANSMITTER THROW
OPTIONAL SET-UP
THROTTLE PROGRAM SELECTION
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 throttle channel
of receiver & ESC. Check throttle channel operation with a
servo. Check wiring sequence of receiver signal harness. Green
& red status LEDs will be both be on solid.
• 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 on solid 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 is too close to speed control, power wires,
or battery––Refer to Step 2.
• Bad connections––Check wiring and connectors.
• External Power Capacitor damaged/not installed––Refer to
Steps 3&7/Replace Power Capacitor (possible internal damage).
Motor and Steering Servo Do Not Work
• Check wires, receiver signal harness wiring and color
sequence, radio system, crystals, battery and motor
connectors, and battery pack.
• Possible internal damage––Refer to Service Procedures.
Speed Control Runs Hot
• Gear ratio too low––Increase ratio (see ‘GEAR SELECTION’).
Model Runs Slowly/Slow Acceleration
• Gear ratio too high––Reduce ratio (see ‘GEAR SELECTION’).
• Check battery connectors––Replace if needed.
• Incorrect transmitter/ESC adjustment––Refer to Steps 4 & 5.
• External Power Capacitor damaged/not installed––Refer to
Steps 3&7/Replace Power Capacitor (possible internal damage).
• 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.
SERVICE PROCEDURES
Before sending in your Super Sport brushless system for service,
review the Trouble-Shooting Guide and instructions. The ESC or
motor may appear to have failed when other problems exist.
After reviewing the instructions, 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
the SERVICE section of the Novak website. Fill out the needed
information on this form and return it with the Novak product
that requires servicing.
PHONE/FAX/E-MAIL: If you do not have access to the internet,
contact our customer service department by phone, fax, or e-
mail as listed in the 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 on it, or an
invoice from previous service work. If warranty provisions have
been voided, there will be service charges.
ADDITIONAL NOTES:
• Super Sport 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 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 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
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 7 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, 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.
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 (closed every other Friday)
(949) 833-8873 • FAX (949) 833-1631
e-mail: [email protected]
web: www.teamnovak.com
©2003 Novak Electronics, Inc. • All Rights Reserved • No part of these operating
instructions may be reproduced without the written permission of Novak
Electronics, Inc. • Super Sport Brushless ESC, 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
speed controls & motors are designed & assembled in the U.S.A.
Printed in the U.S.A. 2/2003 • #IM-3005-1
LOCKED ROTOR DETECTION
The Super Sport system is equipped with Lock Rotor
Detection Circuitry that provides added protection against
overheat damage. Should the vehicle’s drive train become
locked or bound, or for any reason the motor shaft becomes
locked while the throttle is being applied for an extended
period, the Super Sport speed control will cut throttle power
to the motor. This situation could occur when the vehicle
becomes stuck against a tree or wall or jammed underneath
something where the wheels will not spin.
To indicate a locked rotor condition, the Blue & Green status
LEDs will flash six times and then remain on solid. The
transmitter’s throttle trigger must then be returned to the
neutral position before motor control is regained.
GEAR SELECTION (Important)
As a general rule, you can start with the same gear ratio
that you previously had with a “stock” brush-type motor in
your vehicle. The difference is that you now have broad
power band, and can base your gear selection on application
instead of being limited to the narrow RPM range that your
brush-type motor produced its maximum torque. Higher
final drive ratios will give longer run time at the expense of top
speed, while ratios below 6.5:1 will cause excessive heating of
the ESC, and may result in overheating and thermal shut-down.
{ You will want the final drive ratio in the vehicle }
to be about 7.3:1 and not less than 6.5:1
If you had a modified brush-type motor in your
vehicle before switching to the Super Sport system,
and you do not change the gearing, you will be
under-geared and the vehicle will appear slow!
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 bearing sets are available in Novak accessory
kit #5900 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 drop of light oil on
the bearings periodically can help extend bearing life.
ACCESSORIES
POWER CAPACITORS
An external power capacitor is included, and MUST BE USED
to maintain cool and smooth operation. Refer to Step 3
Replacement Power Capacitor is available in Novak kit #5677.
BATTERY/MOTOR 14G POWER WIRE
Replacement silicone power wires for your brushless motor
system are available in Novak kits #5500 (36”red/36”black) ,
#5505 (36”red/36”blue) , & #5510 (36”yellow/36”orange) , or
#5508 (2 each of 9”red/black/blue/yellow/orange) .
INPUT SIGNAL HARNESS
The user-replaceable input signal harness is available in both
short (4.5”) and long (9.0”) lengths to fit different applications.
4.5” harness in Novak kit #5315, and 9.0” harness in kit #5320.
MOTOR BALL BEARING SET
After extensive use, the ball bearings in the end bells of
your brushless motor may need to be replaced.
Two replacement motor bearings are available in Novak kit #5900.
1. REPLACEMENT POWER CAPACITOR INSTALLATION
• Insulate capacitor’s leads with the heat shrink tubing
included in the accessory kit.
• Solder capacitor’s NEGATIVE (–) lead {shorter lead on
capacitor} to the Super Sport’s BLACK PowerCap wire
that comes from the small hole on Super Sport’s Battery
Negative (–) solder tab.
• Solder capacitor’s POSITIVE (+) lead to RED PowerCap wire
that comes from the small hole on Super Sport’s Battery
Positive (+) solder tab.
2. HARD WIRING ESC TO BATTERY PACK
• Cut Super Sport’s BLACK power wire to desired length
and strip 1/8-1/4” of insulation off the end. Solder to
battery NEGATIVE (–) of a charged 4 to 7 cell pack.
• Cut RED power wire to desired length and strip 1/8-1/4”
of insulation off the end. Solder to battery POSITIVE (+).
3. SOLDERING POWER WIRES AT ESC & MOTOR
The Super Sport ESC comes factory wired to the brushless
motor & battery connector. For custom installation or
for power wire replacement:
• Remove power wires from PCB solder tabs
(ESC must
be removed from the model so that you can get access to bottom
side of solder tabs)
. Use a soldering iron to apply heat to
the power wire’s solder joint on the bottom side of the
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 the end of the new wire. Tightly twist
strands of wire, and insert into proper solder tab’s hole
(tabs are identified by lettering that is engraved in the ESC
case and on the end cap of the motor--see photos below)
.
Use soldering iron to apply heat to exposed wire that is
extending 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 the solder
tab (about 1/16” above PCB)-- make sure no strands of wire 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 wires to matching tabs at ESC & Motor (A/B/C) •
• Note: Power wires can also be soldered flat onto the
PCB solder tabs. Strip 3/16-1/4” of insulation from the
end of the new wire. Tightly twist strands of wire, and
tin with solder. Lay the stripped & tinned end of the
wire flat onto the PCB solder tab and use soldering
iron to heat the end of the wire, and add solder to
form a clean solder joint between the wire and the tab.
IMPORTANT NOTE: DO NOT OVERHEAT SOLDER TABS
Prolonged/excessive heating of solder tabs will damage PCB.
4. CHANGING BATTERY CONNECTOR
If you are planning to change the ESC’s Tamiya-style
battery pack connector, we recommend using a high-
quality/low-resistance connector, such as Dean’s Ultra Plug.
Always use a connector that can not be connected backwards!
STEP 7
OPTIONAL SET-UP
OPTIONAL HOOK-UP INSTR.
THERMAL SHUT–DOWN
The Super Sport system is equipped with temperature sensors
in both the ESC and motor to protect from overheating.
Should the ESC or motor become overheated for any reason,
the Super Sport ESC will cut throttle power to the motor.
To indicate thermal shut-down, the Blue status LED will flash
until the ESC or motor returns to within the normal operating
range, at which time throttle power is regained. The
transmitter’s throttle trigger must first be returned to the
neutral position before motor control is regained.
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. If the motor’s sensor
harness become damaged, contact our Customer Service Department.
motor
&
battery
PCB tab
I.D. text
motor
phase
wire
tab I.D.
text
A
B
C
black
orange
white
plastic
tabs
red
blue
green
metal
barbs
raised
metal
barb
metal socket
on end of Teflon
sensor harness wires