SENSOR-BASED DESIGN BENEFITS

SENSOR-BASED DESIGN BENEFITS
BRUSHLESS MOTOR
INSTRUCTIONS
55-3400-1 Rev.9
SENSOR-BASED DESIGN BENEFITS
•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.
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.
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.
NOVAK ELECTRONICS, INC.
Monday-Friday: 8am-5pm (PST) • (949) 833-8873 • FAX (949) 833-1631
e-mail: cs@teamnovak.com
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.
BRUSHLESS MOTOR
INSTRUCTIONS
ACCESSORIES
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.
55-3400-1 Rev.9
SENSOR-BASED DESIGN BENEFITS
•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.
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.
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
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.
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.
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.
NOVAK ELECTRONICS, INC.
Monday-Friday: 8am-5pm (PST) • (949) 833-8873 • FAX (949) 833-1631
e-mail: cs@teamnovak.com
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.
ACCESSORIES
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.
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 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.
OVERHEATING -- WARNING!
INSTALLATION INSTRUCTIONS
1.NO MOTOR CAPACITORS & SCHOTTKY NEEDED
Novak brushless motors do not need motor capacitors or external
Schottky diodes--Schottky diode usage will damage ESC.
2.CHECK MOTOR SCREW LENGTH & INSTALL MOTOR
• Insert the motor mounting screws that came with your vehicle
through the motor mounting plate. 540 & 550-size motors need
no more than 1/8” of screw extending past the vehicle’s mounting
plate (2-4mm)--Too little can strip the motor’s threads, too much
will cause internal motor damage & will void warranty.
• Attach motor to vehicle’s motor mount using one of the sets of
threaded mounting holes--select a mounting position that keeps the
Due to the inherent nature of racing, timing advance speed controls,
brushless motor tolerances/settings, vehicle performance, and track
conditions, it has become virtually impossible to provide accurate
installation and operation recommendations that will allow you to use
these motors at their highest performance levels without the potential
for unwanted damage.
You must, use extreme caution when setting up these electronics and
carefully test your application to avoid overloading and overheating
either the speed control or the motor.
These are racing electronics used in racing conditions, and therefore
damage as the result of excessive overheating WILL NOT be covered
under the product’s factory warranty.
solder tabs clear of conductive surfaces like aluminum or graphite.
3.INSTALL PINION GEAR (see GEAR SELECTION on back)
Install pinion on motor and test fit in vehicle to align pinion and
spur gears. Tighten pinion’s set screw on the flat of motor shaft.
4.ADJUST MOTOR FOR PROPER GEAR MESH
• Adjust the motor position for proper amount of free play. You
NEED to have a small amount of play between the pinion gear
and the spur gear (about the thickness of piece of paper)--check
the free play at several positions around the spur gear to
ensure a proper mesh (just in case the gears are out of round).
MAKE SURE THE PINION/SPUR GEAR MESH IS NOT TOO TIGHT!
If gear mesh is too tight, motor shaft breakage can occur.
If you do not change gearing after switching to brushless, you will be
over-geared and will have slow acceleration & excessive temperatures!
A
C
B
Because of the broad power band of brushless, you can go 1-2 teeth higher
pinion than the above recommendations for more top speed, but remember
any higher will produce excessive ESC & motor heating. Check the motor’s
operating temperature after making any gearing adjustments--motors are
designed to operate from 160ºF-175ºF maximum.
motor
phase
wire
tab I.D.
text
Crawler Brushless Motors
IMPORTANT NOTE: DO NOT OVERHEAT SOLDER TABS
When properly geared for use with gear reduction transmissions found in rock
crawling vehicles, your brushless crawler motor and ESC should not get very
hot--if you notice excessive temperatures, check motor & drive train for free
operation or adjust gearing to lower temperature.
Prolonged/excessive heating of solder tabs will damage PCB & void warranty.
SENSOR HARNESS WIRING
Should any of the 26G Teflon wires pull out of the motor’s sensor
harness connector, re-insert them in the connector’s appropriate
slot as shown below. There is a small plastic tab that grabs a small
raised barb on the back of the metal socket crimped onto the Teflon
wire’s end. Check the plastic tab to make sure it has not deformed
excessively before inserting the socket into the plastic connector
housing with the barb toward the plastic tabs.
black
orange
white
plastic
tabs
red
blue
green
metal
barbs
raised
metal
barb
metal socket on end of
Teflon sensor harness wires
MAKE SURE THE PINION/SPUR GEAR MESH IS NOT TOO TIGHT!
Because of the potential danger of overheating, ESC/motor damage & failure,
you must start with VERY small pinion sizes and check ESC & motor
temperatures at multiple times throughout a run. This is the only way to
ensure that you are not causing excessive heating.
If ESC & motor temperatures remain low & stable, you can slowly increase
the pinion size while again monitoring the temperatures to determine the safe
gearing for your vehicle, motor, and climate/track conditions. Because these
variables can change or be modified, you MUST continually monitor ESC &
motor temperatures to protect your electronics from damage.
will cause short-circuiting, damage electronics, & void product’s warranty.
Be sure to solder wires
to matching tabs at
ESC & Motor (A/B/C)
The motor should be 160-175°F MAX at end of run!
Change the gearing to avoid overheating.
Three-80 Micro Pro Brushless Motors
A safe starting point for gearing is 3-5 teeth smaller than the stock pinion gear
that came with your micro vehicle. When properly geared, your Three-80
system should not get excessively hot--if you notice high temperatures, check
motor & drive train for free operation or adjust gearing to lower temperature.
550-size (high-voltage) Brushless Motors
Novak 550 motors should be geared based on the end-of-run motor & ESC
temperatures--adjust gearing so the temperatures do not exceed 160-170°F.
If installing in the Traxxas® E-MaxxTM, start with the following:
Original E-MaxxTM:
72 spur gear
12T pinion
New version E-MaxxTM:
68 spur gear (stock)
12T pinion
See our website for updated gearing recommendations, final
drive ratios, or if your motor does not appear above.
www.teamnovak.com
Due to the inherent nature of racing, timing advance speed controls,
brushless motor tolerances/settings, vehicle performance, and track
conditions, it has become virtually impossible to provide accurate
installation and operation recommendations that will allow you to use
these motors at their highest performance levels without the potential
for unwanted damage.
You must, use extreme caution when setting up these electronics and
carefully test your application to avoid overloading and overheating
either the speed control or the motor.
These are racing electronics used in racing conditions, and therefore
damage as the result of excessive overheating WILL NOT be covered
under the product’s factory warranty.
solder tabs clear of conductive surfaces like aluminum or graphite.
Motor operating temperature is the ONLY
way to properly set the vehicle gearing
Temperatures above 175°F will weaken the magnet & may
melt the coils! This voids warranty & can damage ESC!
• Tighten motor mounting screws--Avoid using excessive force,
as the threaded holes in motor could become stripped.
5.SOLDER 540/550 MOTOR WIRES & CONNECT SENSOR HARNESS
• Determine the best routing in vehicle for sensor harness & power
wires. Prepare ends of motor power wires by stripping 1/81/4” of insulation from end of wire. Tin wire ends with solder.
• Lay tinned end of the wire flat on the solder tab and solder wires
to proper tabs of the motor (see photo below). Apply heat with
soldering iron to the power wire and solder tab--begin adding
solder to tip of iron and to wire--Add just enough solder to form a
clean & continuous joint from the solder tab up onto the wire.
WARNING: Be sure no wire strands have strayed to an adjacent solder tab--this
1.NO MOTOR CAPACITORS & SCHOTTKY NEEDED
Novak brushless motors do not need motor capacitors or external
Schottky diodes--Schottky diode usage will damage ESC.
2.CHECK MOTOR SCREW LENGTH & INSTALL MOTOR
• Insert the motor mounting screws that came with your vehicle
through the motor mounting plate. 540 & 550-size motors need
no more than 1/8” of screw extending past the vehicle’s mounting
plate (2-4mm)--Too little can strip the motor’s threads, too much
will cause internal motor damage & will void warranty.
• Attach motor to vehicle’s motor mount using one of the sets of
threaded mounting holes--select a mounting position that keeps the
3.INSTALL PINION GEAR (see GEAR SELECTION on back)
Install pinion on motor and test fit in vehicle to align pinion and
spur gears. Tighten pinion’s set screw on the flat of motor shaft.
4.ADJUST MOTOR FOR PROPER GEAR MESH
• Adjust the motor position for proper amount of free play. You
NEED to have a small amount of play between the pinion gear
and the spur gear (about the thickness of piece of paper)--check
the free play at several positions around the spur gear to
ensure a proper mesh (just in case the gears are out of round).
GEAR SELECTION (Important)
OVERHEATING -- WARNING!
INSTALLATION INSTRUCTIONS
GEAR SELECTION (Important)
Motor operating temperature is the ONLY
way to properly set the vehicle gearing
The motor should be 160-175°F MAX at end of run!
If gear mesh is too tight, motor shaft breakage can occur.
Temperatures above 175°F will weaken the magnet & may
melt the coils! This voids warranty & can damage ESC!
• Tighten motor mounting screws--Avoid using excessive force,
as the threaded holes in motor could become stripped.
5.SOLDER 540/550 MOTOR WIRES & CONNECT SENSOR HARNESS
• Determine the best routing in vehicle for sensor harness & power
wires. Prepare ends of motor power wires by stripping 1/81/4” of insulation from end of wire. Tin wire ends with solder.
• Lay tinned end of the wire flat on the solder tab and solder wires
to proper tabs of the motor (see photo below). Apply heat with
soldering iron to the power wire and solder tab--begin adding
solder to tip of iron and to wire--Add just enough solder to form
a clean & continuous joint from the solder tab up onto the wire.
WARNING: Be sure no wire strands have strayed to an adjacent solder tab--this
Change the gearing to avoid overheating.
Because of the potential danger of overheating, ESC/motor damage & failure,
you must start with VERY small pinion sizes and check ESC & motor
temperatures at multiple times throughout a run. This is the only way to
ensure that you are not causing excessive heating.
If ESC & motor temperatures remain low & stable, you can slowly increase
the pinion size while again monitoring the temperatures to determine the safe
gearing for your vehicle, motor, and climate/track conditions. Because these
variables can change or be modified, you MUST continually monitor ESC &
motor temperatures to protect your electronics from damage.
will cause short-circuiting, damage electronics, & void product’s warranty.
Be sure to solder wires
to matching tabs at
ESC & Motor (A/B/C)
If you do not change gearing after switching to brushless, you will be
over-geared and will have slow acceleration & excessive temperatures!
A
C
B
Because of the broad power band of brushless, you can go 1-2 teeth higher
pinion than the above recommendations for more top speed, but remember
any higher will produce excessive ESC & motor heating. Check the motor’s
operating temperature after making any gearing adjustments--motors are
designed to operate from 160ºF-175ºF maximum.
motor
phase
wire
tab I.D.
text
Crawler Brushless Motors
IMPORTANT NOTE: DO NOT OVERHEAT SOLDER TABS
When properly geared for use with gear reduction transmissions found in rock
crawling vehicles, your brushless crawler motor and ESC should not get very
hot--if you notice excessive temperatures, check motor & drive train for free
operation or adjust gearing to lower temperature.
Prolonged/excessive heating of solder tabs will damage PCB & void warranty.
SENSOR HARNESS WIRING
Should any of the 26G Teflon wires pull out of the motor’s sensor
harness connector, re-insert them in the connector’s appropriate
slot as shown below. There is a small plastic tab that grabs a small
raised barb on the back of the metal socket crimped onto the Teflon
wire’s end. Check the plastic tab to make sure it has not deformed
excessively before inserting the socket into the plastic connector
housing with the barb toward the plastic tabs.
black
orange
white
plastic
tabs
red
blue
green
metal
barbs
raised
metal
barb
metal socket on end of
Teflon sensor harness wires
Three-80 Micro Pro Brushless Motors
A safe starting point for gearing is 3-5 teeth smaller than the stock pinion gear
that came with your micro vehicle. When properly geared, your Three-80
system should not get excessively hot--if you notice high temperatures, check
motor & drive train for free operation or adjust gearing to lower temperature.
550-size (high-voltage) Brushless Motors
Novak 550 motors should be geared based on the end-of-run motor & ESC
temperatures--adjust gearing so the temperatures do not exceed 160-170°F.
If installing in the Traxxas® E-MaxxTM, start with the following:
Original E-MaxxTM:
72 spur gear
12T pinion
New version E-MaxxTM:
68 spur gear (stock)
12T pinion
See our website for updated gearing recommendations, final
drive ratios, or if your motor does not appear above.
www.teamnovak.com
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