Novak Brushless Speed Control: Crusher Basic Set-Up (original) (55-1833-1 Rev.2) - Manual

#55-1833-1 Rev.2
1-2014
SPECIFICATIONS
Input Voltage ....................... 2-4S LiPo cells (External BEC required for 3-4S operation)
Motor Compatibility .............Sensor-based brushless (Novak Crawler for Crawler Mode)
Motor Limit (2S).......................................6.5T 540-size (13.5T Crawler); 4.5T 550-size
Motor Limit (3S).....................................13.5T 540-size (18.5T Crawler); 6.5T 550-size
Motor Limit (4S).....................................13.5T 540-size (18.5T Crawler); 7.5T 550-size
ESC Footprint & Height ......................1.16” x 1.47” x 0.96”H (29.5 x 37.3 x 24.4mm)
ESC Weight (w/o wires).......................................................... 1.42 ounce (40.4 grams)
B.E.C. Voltage/Current ............................................................6.0 volts DC / 5.0 amps
Power Wire (Battery/Motor) ..................................................... 14G Super-Flex Silicone
On-Resistance .............................................. 0.0004ohm per phase @25°C trans.temp.
The Crusher Brushless ESC includes both Rock Crawling & Sport Driving Modes,
RPM Boost Timing to electronically advance the motor timing at full-throttle for
explosive top speeds, Novak’s exclusive X-Drive, and is compatibile with both 540
and 550-size sensor-based brushless motors & Novak Crawler motors.
•This ‘Basic Set-Up Guide’ will get your Crusher installed and adjusted to your transmitter•
When ready for complete ESC programming, the ‘Crusher Field Guide’ is available in
the Downloads section of our web site (www.teamnovak.com), where it can be viewed or
printed and will guide you through all of the Crusher’s adjustable parameters.
(Please contact our Customer Service if you don’t have internet access or have trouble viewing the ESC Field Guide)
PLUG-IN INPUT SIGNAL HARNESS (JST-JST) [Novak kits #5315 & #5320]
Input signal harness with JST connector on both ends--4.5” (#5315), 9” (#5320).
BRUSHLESS MOTOR CONNECTOR WIRE SET [Novak kit #5332]
Flexible 14GA wire with gold-plated connectors for low-resistance connections.
BRUSHLESS SENSOR HARNESSES [Novak kit #5351-#5353]
Shielded sensor harness protects sensor wires--4” (#5351), 6” (#5352), 9” (#5353).
3A HIGH-VOLTAGE UNIVERSAL BEC (2-7S) [Novak kit #5463]
Supplies 6.0V / 3A of power to receiver & servo for extra performance under heavy loads.
SUPER-FLEX SILICONE 14GA WIRE SET [Novak kit #5508]
Two each of 9” length black, red, blue, yellow, and orange 14GA wire.
ESC POWER SWITCH HARNESS [Novak kit #5600]
Includes replacement ON/OFF Power Switch with stripped & tinned wire harness.
GLITCH BUSTER CAPACITOR [Novak kit #5626] *HIGHLY RECOMMENDED*
Supplies reserve power to receiver during spikes of heavy servo load to avoid drop-out.
25x25x10mm COOLING FANS [Novak kits #5647 & #5651]
Cooling fans with JST power plug. Single fan (#5647), 2-pack of fans (#5651).
POWER CONNECTORS–3.5mm & 4mm [Novak kit #5731 & #5741]
Low-Loss connectors generate dozens of wiring routing and installation options.
LEAD-FREE SILVER SOLDER [Novak kit #5831-#5833]
3% Silver solder for high-conductivity--6gr (#5831), 15gr (#5832), 100gr (#5833).
MOUNTING TAPE 25x35mm [Novak kit #5840 & #5841]
Cushioned, double-sided tape for mounting electronics--10pc (#5840), 100pc (#5841).
HEAT SHRINK TUBING [Novak kit #5850 & #5851]
6” long heat shrink tubing in six sizes: 1/16” - 3/8”--6pc kit (#5850), 24pc kit (#5851).
WATER & ELECTRONICS DON’T MIX!
Allowing water, moisture or other foreign materials to get inside ESC will void warranty.
MUST BE 14 YEARS OR OLDER TO OPERATE
Strict adult supervision is required for use by children under 14 years of age.
SENSOR-BASED BRUSHLESS MOTORS ONLY
Designed for use with 540 & 550-size sensor-based Novak brushless motors.
For optimal Crawler Mode performance, earlier Novak Ballistic Crawler motors MUST
have the mechanical motor timing set to 0°--Loosen bearing cap & adjust timing to where
the sensor harness connector is directly in-line with the center (Phase B) solder tab.
NEVER USE SCHOTTKY DIODES WITH BRUSHLESS ESCs!
DO NOT FREE REV OR OPERATE WITHOUT LOAD!
This includes running the motor without a pinion or holding the car in the air and
running the motor at or close to full power. Free revving will void the warranty!
2-4S LiPo CELLS ONLY--Ext.BEC Recommended w/Heavy Servo Loading
NEVER exceed 4S LiPo packs (with the proper turn motors only!) --Be sure Voltage Cut-Off option
is turned ON (refer to Field Guide) . For NiCd/NiMH, disable the Voltage Cut-Off circuitry.
GOOD QUALITY RADIO & LiPo BATTERIES SUGGESTED
Undesirable radio noise may occur when using lower quality radio systems. 2.4GHz radio
system use is best; high quality FM system is acceptable; AM systems are NOT recommended.
LiPo’s that can’t supply the required amperage can damage electronics & voids warranty.
UNPLUG BATTERY WHEN NOT IN USE & SWITCH ESC OFF
Always disconnect batteries from ESC to avoid short circuits and possible fire hazard.
ALWAYS SWITCH OFF ESC BEFORE CONNECTING BATTERY
If battery is connected with ESC switch in ON position, serious damage can occur.
DO NOT BUNDLE POWER & SIGNAL WIRES TOGETHER
RF noise in the power wires can adversely effect radio system performance.
DISCONNECT MOTOR BEFORE BINDING or ONE-TOUCH
Motor may receive full throttle signal if connected to ESC & damage or injury can occur.
TRANSMITTER ON FIRST
Turn on transmitter power first so you will have control of vehicle when you turn it on.
INSULATE WIRES & NO REVERSE VOLTAGE!
Insulate exposed wiring with heat shrink tubing or electrical tape to prevent short circuits,
& never reverse connect the battery--ESC damage will occur & void warranty.
POWERCAP REQUIRED/GLITCH BUSTER SUGGESTED
On-Board PowerCaps are installed on ESC & MUST be used at all times to avoid high ESC
temperatures & possible damage. Use of a Glitch Buster helps with heavy BEC loading.
NO CA GLUE
CA glue or fumes can damage internal components of ESC & cause premature failure.
BASIC SET-UP GUIDE ––– crusher
• Download “ESC Field Guide” from our web site for Proper Gearing & Custom Programming • Read All Instructions Before Use •
PRECAUTIONS
ACCESSORIES
product warranty
This Brushless ESC is guaranteed to be free from defects in materials or workmanship for a period of 120 days
from original purchase date (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 more
than 4 LiPo cells input voltage, damage from using motors with too few of turns for the battery being used,
damage resulting from using LiPo batteries without Smart-Stop voltage cut-off circuitry active, using insufficient
LiPo batteries that cannot supply the amperage required by this system, cross-connection of battery/motor
power wires, overheating solder tabs, reverse voltage application, improper use or installation of external
BEC, damage resulting from thermal overload or short-circuiting motor, damage from incorrect installation
of FET servo or receiver battery pack, damage due to free revving motor, damage due to using a non-Novak
motor or a non-sensored motor, incorrect installation of a PowerCap or Power Trans-Cap Module on ESC or
operating ESC with a damaged PowerCap, using a Schottky diode, 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 has no control over connection & use of ESC or other related electronics, no liability may be
assumed nor will be accepted for any damage resulting from the use of this product. Every Novak ESC & motor
is thoroughly tested & cycled before leaving our facility and is, therefore, considered operational. By the act of
connecting/operating ESC, 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. This product is not intended
for use by children under 14 years of age without the strict supervision of an adult. Use of this product in an
uncontrolled manner may result in physical damage or injuries—take extra care when operating any remote
control vehicle. Melted ESCs/motors are not covered by the warranty.
Designed by Novak R/C, Inc. in California and assembled with globally sourced components.
©2014 Novak R/C, Inc. • All Rights Reserved • No part of these instructions may be reproduced without
the written permission of Novak R/C, Inc. Crusher Brushless ESC, Hall Sensor Test, & One-Touch Set-Up
are all trademarks of Novak R/C, Inc.
VOLTAGE cUt-OFF circuitry
When active, the built-in Auto-Detect Smart-Stop Voltage Cut-Off Circuitry lets
you safely use 2S-4S Lithium Polymer (LiPo) battery packs by cutting off the ESC’s
throttle output when the critical safety voltage is reached. The circuitry monitors the
battery pack voltage and automatically selects a 2S, 3S, or 4S cut-off voltage value.
When the ESC detedts that the critcial safety voltage will soon be reached, it begins
interrupting, or “blipping” the throttle output as an early warning that the battery’s
voltage is getting low and the throttle output will soon be completely shut off.
When the critical voltage is reached, the throttle output to the motor gets
completely shut down to keep the voltage from dropping further.
Re-charge battery after Smart-Stop circuitry shuts off throttle
Even though the pack’s voltage will rise (after a short resting period) to a level high
enough to run motor again, this is not good for LiPo or LiFe batteries.
Reaching critical safety voltage too many times can damage the cells.
DO NOT RUN VEHICLE AFTER SMART-STOP HAS SHUT DOWN THROTTLE OUTPUT!
When the ESC is switched ON, the Yellow & Red LEDs will flash together
2 to 4 times to indicate LiPo Cut-Off is ACTIVE and # of cells connected.
With the Voltage Cut-Off turned ON & using NiCd/NiMH cells, the ESC’s throttle output will
shut off very early into the run--Change the Cut-Off Circuitry mode to OFF to use these batteries.
See CUSTOM PROGRAMMING OPTIONS on ESC Track Guide to properly adjust this setting.
OPTIONAL RECEIVER PACK USAGE
To use an external receiver battery pack to power the electronics:
1. Plug the 5 cell (1.2VDC/cell) receiver pack into the battery slot of the receiver.
2. Switch the receiver pack ON. Next, turn the ESC’s switch ON, then OFF to
allow the ESC to be powered by the external power source.
3. Turn the receiver pack’s switch OFF to turn the vehicle OFF.
ALTERNATIVE METHOD
1. Plug the 5 cell (1.2 VDC/Cell) receiver pack into the battery slot of the receiver.
2. Unplug the ESC’s red wire from input receiver harnesse (insulate the red wire).
3. To turn the vehicle ON, switch the receiver pack ON. Then, turn the ESC’s switch ON.
4. To turn vehicle OFF, turn ESC’s switch OFF, then turn receiver pack’s switch OFF.