Novak HV4400 and 7XL BL Sensored System...

[GriffinRU]

Sorry for delay,

To setup sensored HV controller to work with sensoreless motor you need to provide sensors feedback. In my case I choose to use brushless sensored motor which comes with HV system. (Later sensored BL motors should be available…)
Installation of both motors requires to accomplish that task, shaft connection would be done via spur gear and pinion gears (master and slave motors must have pinions with the same number of teeth).
Step by step:
- mount both motors to tranny mount
- connect motor wires together
- spin one motor shaft and check for slave shaft
In most cases it should be easy to match, if not get as close as you can.
- install spur gear
- connect with power meter 6 cells to ESC
- unsolder Novak's motor and solder New motor to Novak's ESC
- turn on power
- Push throttle until wheels start spinning or motor wires start moving (turn of ESC) forward and measure current (remember value).
- Reverse throttle, until the same parameters above, and measure current.
If forward and reverse currents equals each other then timing set correct and no further adjustments required. If not, then adjusting one tooth at a time, with measuring will help to find 0 degrees mark. Setting to zero degree mark is must if reverse option would be used and not if forward only, but less teeth on pinion fewer adjustments to timing can be made due to the Novak’s ESC automatic timing adjustment at middle RPM. Setting too aggressive can force motor to reverse…. Not really and not good, just reminder.

Now when 0 timing found you can mark both shafts, by putting ruler on both shafts and marking shaft with permanent marker or scratching it, whatever works to identify shafts relation. After that you can take setup apart and put back together without going through process described above again.

With 7XL and 12 cells I was able to make motor move in both directions with current draw as low as 0.6A. One tooth left-right with 18 teeth pinion can easily change this ration to 4A and 0.8A respectfully. So do not be scared, but be careful and watch for moving wires (not good).

Artur

P.S. Open for questions and help.

[BrianG]

Originally Posted by GriffinRU

Sorry for delay,

To setup sensored HV controller to work with sensoreless motor you need to provide sensors feedback. In my case I choose to use brushless sensored motor which comes with HV system. (Later sensored BL motors should be available…)
Installation of both motors requires to accomplish that task, shaft connection would be done via spur gear and pinion gears (master and slave motors must have pinions with the same number of teeth).
Step by step:
- mount both motors to tranny mount
- connect motor wires together
- spin one motor shaft and check for slave shaft
In most cases it should be easy to match, if not get as close as you can.
- install spur gear
- connect with power meter 6 cells to ESC
- unsolder Novak's motor and solder New motor to Novak's ESC
- turn on power
- Push throttle until wheels start spinning or motor wires start moving (turn of ESC) forward and measure current (remember value).
- Reverse throttle, until the same parameters above, and measure current.
If forward and reverse currents equals each other then timing set correct and no further adjustments required. If not, then adjusting one tooth at a time, with measuring will help to find 0 degrees mark. Setting to zero degree mark is must if reverse option would be used and not if forward only, but less teeth on pinion fewer adjustments to timing can be made due to the Novak’s ESC automatic timing adjustment at middle RPM. Setting too aggressive can force motor to reverse…. Not really and not good, just reminder.

Now when 0 timing found you can mark both shafts, by putting ruler on both shafts and marking shaft with permanent marker or scratching it, whatever works to identify shafts relation. After that you can take setup apart and put back together without going through process described above again.

With 7XL and 12 cells I was able to make motor move in both directions with current draw as low as 0.6A. One tooth left-right with 18 teeth pinion can easily change this ration to 4A and 0.8A respectfully. So do not be scared, but be careful and watch for moving wires (not good).

Artur

P.S. Open for questions and help.

That sounds pretty straightforward. I wouldn't even thought about the timing, but it makes sense once you explain it. I was telling one of the guys at my LHS about what you did and he was pretty interested once I explained it to him a few times (wasn't getting it at first). Have you tried to pull the windings out of the slave motor to save a little bit of weight? Of course, you'd have to be careful not to wreck the hall-effect sensor...

[GriffinRU]

Originally Posted by BrianG

That sounds pretty straightforward. I wouldn't even thought about the timing, but it makes sense once you explain it. I was telling one of the guys at my LHS about what you did and he was pretty interested once I explained it to him a few times (wasn't getting it at first). Have you tried to pull the windings out of the slave motor to save a little bit of weight? Of course, you'd have to be careful not to wreck the hall-effect sensor...

Thank you, I was trying to put it that way ..:)

I ordered from E-Bay horizontally magnetazed neodym rings and will try to build custom sensor feedback. Taking HV4400 motor apart, I think is just waste of time. If you creative then use it as generator to keep your RX power pack happy :)

7XL on 12 cells just slow... and brakes need to be trimmed on TX side

I need to replace it with smaller motor (Hacker C50 14.4 is coming) and ditch 2 speed tranny :) (Personal opinion!)

Artur

P.S. Hey guys do I miss something? I run stock (shimmed) diffs and trashing CVD's... Doesn't sound right or ...