Novak Brushless Conversion Kit (55-5010-1) - Manual

STEP 5 - INSTALL ESC & RECEIvER BRUSHLESS CONvERSION KIT INSTRUCTIONS
CONvERSION KITS AvAILABLE
The following Novak Brushless Conversion Kits are available (Refer to
www.teamnovak.com for additional and/or updated kit compatibility information)
#5010 Associated
® RC8 TM for Team Associated RC-8 Buggy
#5011 CEN ® Matrix TM for CEN Matrix C-1 Buggy
#5012 Hot Bodies ® Lightning TM for Hot Bodies Lightning2 Evo Pro Buggy
#5013 Kyosho ® Inferno TM for Kyosho Inferno 777, 777 SP-1, SP-2,
SP-2WC, and Sport ST-R Buggies
#5014 Mugen ® MBX5 TM for Mugen MBX5 and MBX5R Buggies
#5015 OFNA ® 9.5 TM /Ultra TM for OFNA 9.5 Series Buggies (Violator TM ,
Ravenger TM and Jammin X1 TM ) and the OFNA Ultra Series Buggies (MBX TM ,
Comp TM and LX1 TM )
#5016 OFNA ® Hyper 8 TM for OFNA Hyper 8 and Hyper 8.5 Buggies
#5017 OFNA ® Hyper 7 TM for OFNA Hyper 7 Buggies
#5018 XRAY ® XB8 TM for X-Ray XB8 TQ and XB8 EC Buggies
#5019 Losi ® 8ight TM for Team Losi 8ight Buggy
Car models listed are the registered trademarks of their respective company.
The Ultimate Conversion Kit to Convert Nitro Buggies to Electric Power!
Novak’s Brushless Conversion Kits allow drivers to experience the benefits of brushless with a leaner, cleaner, less noisy 1/8-scale car with faster acceleration and
speeds comparable to nitro. The Novak Brushless Conversion Kits were designed specifically for Novak’s 550-size, HV-Series of sensored brushless motors and
include all of the necessary conversion components. A Novak High-Voltage Brushless ESC and HV Brushless Motor are not included but required for completion.
#55-5010-1 • 4/2008
GEARING SETUP
1. INSTALL NOVAK HV BRUSHLESS ESC
a. Select mounting position for ESC — refer to Figure 14 (on
specifics sheet).
• For OFNA & Kyosho Dual Battery Setups: refer to Figure 15
• For Losi 8ight: refer to Figures 20 & 21 (on specifics sheet).
Note: Be sure there is adequate
ventilation over ESC’s heat sink!
b. Using the included double-sided tape, mount ESC to chassis.
• ESC can be mounted to chassis with the included #6x1”
Phillips FH self-tapping screws (see Figure 13) — chassis
and/or stone guard will need to be drilled and holes
countersunk to do this.
c. Refer to the ESC instructions for further installation instructions.
2. INSTALL RECEIVER AND ANTENNA MOUNT
a. Select mounting position for receiver and antenna — refer to
Figure 14 (on specifics sheet).
• For OFNA & Kyosho Dual Battery Setups: refer to Figure 15
• For Losi 8ight: refer to Figure 14 (on specifics sheet).
b. Install Receiver: refer to receiver instructions.
c. Using a 2.0mm Hex Wrench, install plastic antenna mount (in
Add’l Hardware Bag — refer to Figure 13), using the M3x8 FH
screw. Drill out the other hole (as needed) to fit the antenna
tube that came with nitro vehicle.
Qualit y Racing Electronics since 1978
NOvAK ELECTRONICS, INC.
Monday-Friday: 8:00am-5:00pm (PST) • (949) 833-8873 • FAX (949) 833-1631
E-MAIL: [email protected] • WEB: www.teamnovak.com
3. INSTALL MOTOR PINION GEAR
Install a Mod 1 pinion gear to the output shaft. A hardened steel,
high-strength pinion gear is recommended with a 5mm bore. Novak
offers these pinion gears in 11T-16T (Novak #5100-#5105) . Refer to
Figure 14 (on specifics sheet) for recommended pinion gear.
4. INSTALL BRUSHLESS MOTOR ASSEMBLY
Each kit has a unique motor adapter plate.
• Slotted Plates: require four M4x10 FH screws and four M4
Nylon insert lock nuts — see Figure 12.
• Non-Slotted Plates: require the four screws (and cupped washers
depending on model) that were originally used to mount the nitro engine
to the chassis. Use thread-locking agent on these screws.
Mount motor assembly to chassis with the proper screws and
adjust gear mesh before tightening, being sure that the two
clamping screw holes in the heat sink face the outside of the
buggy. The motor’s solder tabs should face in the direction that
will provide the shortest wire length from the ESC to the motor.
• For Losi 8ight Vehicle: refer to Figures 17-19 (on specifics sheet).
figurE 12: Motor Adapter Plate Installation (slotted plate shown)
Note: Motor and Heat Sink removed to show screw detail
5. INSTALL MOTOR FAN ON HEAT SINK
For optimal performance, place the included 40x40mm fan square
and flush on top of heat sink (refer to label on fan for direction) .
• Using a 3/32” Hex Wrench, screw four 4-40x1/2” socket cap
screws (in Add’l Hardware Bag) through fan into heat sink — see
Figure 11 & Figure 14 (on specifics sheet).
• Use included Y-harness (see Figure 1) to plug the motor fan and
ESC fan into the Novak HV High-Voltage Brushless ESC.
4-40x1/2” Socket Cap Screw (4)
#6x1” Phillips FH Self-Tapping
Screw (2)
M3x8 FH Screw (1)
Antenna Mount (1)
Servo Stand-Offs (4)
figurE 13: Additional Hardware Bag Contents (#65-5010-3)
Note: For non-slotted plates, use the hardware that was included with
your Nitro engine. Do not use M4x10 FH screws of M4 lock nuts.
For slotted plates, use
four, M4x10 FH screws
and four M4 lock nuts.
P1 P4
figurE 11:
Motor Heat Sink
Installed on
Motor Adapter
Plate
Back endbell must be on
same side as engraved
name on motor plate
Motor fan mounts square and
flush on heat sink using four
4-40x1/2” socket cap screws.
Fan shown above heat sink
to show screw detail.
M3x8 FH
screws (4)
Refer to Vehicle Specifics Sheet for Novak’s
recommended gearing Starting Points.
Motor operating temperature is the
ONLY way to set vehicle gearing
BE SurE TO CrEATE
SuffiCiENT VENTiLATiON
The Motor and Speed Control should not exceed
160-170°f MAX at end of the run!
Change the gearing to avoid overheating!
DO NOT frEE-rEV MOTOr!
Free-running your brushless motor in a no-load condition can cause rotor
failure & ESC transistor damage and will void the product’s warranty.
• RoToRy/DREMEl Tool
WITH CUT-OFF WHEEL ANd
SANdINg dRUM
• PoWER HaND DRill
• 3.6mm oR 9/64” DRill BiT
• 4mm oR 5/32” DRill BiT
• 3/32” HEX WRENCH
• 3.0mm HEX WRENCH
• 2.5mm HEX WRENCH
• 2.0mm HEX WRENCH
• PHilliPS SCREWDRiVER
• 90
O COUNTER SINK TOOL
• THREaD-loCKiNg agENT
PLEASE rEAD ALL iNSTruCTiONS BEfOrE STArTiNg
VEHiCLE CONVErSiON. The instructions for this
conversion kit are guidelines for installation. Some
customization and variance may be needed.
MuST BE 18 YEArS Or OLDEr
Installation of this kit requires the use of power tools. Adult supervision is
required for users under the age of 18.
NOVAK 550-SiZE MOTOrS ONLY
The motor heat sink included in this kit was specifically developed for Novak
550-size, HV-Series of Brushless Motors. Use of the heat sink on other
motors may cause damage to the motor.
MAY VOiD VEHiCLE’S WArrANTY
Refer to the warranty statement of your vehicle’s owner’s manual.
fOLLOW ESC & MOTOr PrECAuTiONS
Refer to Novak’s “Precaution” sections of instruction manuals.
HigH QuALiTY BATTEriES ONLY!
Stick type or pre-assembled NiMH sport packs are NOT RECOMMENDED.
Novak recommends using high quality (20C minimum) li-Poly battery packs
for better balance, lower vehicle weight and longer run times.
*HV4.5 is for high-speed runs only
PRECAUTIONS
ProducT WArrAnTy
This product 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). War-
ranty does not cover incorrect installation, components worn by use, or any damage caused
by a crash, flooding or natural disaster. Because Novak has no control over the installation of
this conversion kit, no liability may be assumed nor will be accepted for any damage resulting
from the use of this product. By the act of installing the components of this conversion kit, 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.
©2008 Novak Electronics, inc. • all Rights Reserved • No part of these instructions may be
reproduced without the written permission of Novak Electronics, Inc.
TOOLS NEEdEd
ACCESSORIES
MOD 1 PINION GEARS FOR 5MM SHAFT [Novak #5100-5105]
HV BRUSHLESS MOTOR 5MM UPGRADE KIT [Novak #5924]
SUPER-FLEX SILICONE 14G WIRE [Novak kits #5500 & 5508]
LEAD-FREE 3% SILVER SOLDER [Novak kit #5830]
INCLUdEd ITEMS
a. MOTOR
HEAT SINK
b. MOTOR
ADAPTER
PLATE
c. BATTERY
BOXES (2)
d. BATTERY BOX
STRAPS (2)
e. MOTOR
COOLING FAN
f. Y-HARNESS
THERMAL PASTE,
MOUNTING TAPE
& ZIP TIES*
a
c
b
d
e
f
*not shown
figurE 1: Included Items
There are four Hardware Bags included and are detailed in the
relevant instruction sections.
noVAK HV BruSHLESS SySTEM rEQuIrEd
This kit requires a Novak HV Brushless ESC and
a 550-size HV Brushless Motor for completion.
Compatible Novak HV Brushless Motors:
• HV4.5*, HV5.5, HV6.5, or HV7.5 High-Voltage
Brushless Motor with 5mm shaft (#3524-3527)
• HV4.5* & HV6.5 High-Voltage Brushless Motors
(#3424 & #3426) and HV4400 (original). These
motors have a 1/8” shaft and need to be updated
with a 5mm rotor with Novak #5924 Upgrade Kit.
STEP 4 INSTALL BRUSHLESS MOTOR (Continued)
2. ATTACH HEAT SINK TO ADAPTER PLATE
Using a 2.0mm Hex Wrench and four M3x8 FH screws, attach the
motor’s heat sink on to the motor adapter plate — the motor’s
back endbell (end with sensor harness) must be on the side of the
engraved name. Screw thread locking agent should be used
on these screws to prevent loosening — see Figure 11.