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

black wire
(Rx negative)
red wire
(Rx positive)
white wire
(Rx signal)
positive fan wire
negative fan wire
one-touch
button status
LEDs
step 2–connect motor/battery
step 1–mount esc
Mount the ESC so the power wires are as far away from other electronics as
possible, and they will not interfere with the vehicle’s moving parts. Select a
location with good airflow for cooling the ESC for efficient operation.
1. MOUNT SPEED CONTROL IN VEHICLE
Use the included double-sided tape to mount ESC in vehicle (do not use glue).
Avoid contact with side walls or chassis components to avoid vibration damage.
Be sure receiver & antenna are mounted as far from ESC, power wires, battery,
and servo as possible--These components all emit RF noise.
Note: Mount antenna as close to receiver as possible--trail excess wire off top of
antenna mast (cutting/coiling excess wire reduces radio range--2.4GHz too).
2. INSTALL ON/OFF SWITCH
Use included double-sided tape or a screw to mount switch that will be
easy to access--select a place where it will not get damaged/switched OFF in a crash.
3. SECURE POWER WIRES TO AVOID DAMAGE
Use the included tie-wraps to secure the ESC’s power wires together or to
a point on the vehicle to avoid possible damage to wires & solder joints.
Motor connection
1. SELECT PROPER MOTOR FOR OPTIMUM PERFORMANCE
The ESC’s Crawler Mode ONLY works with Novak Ballistic Crawler brushless motors,
AND works best with motors set to 0° mechanical timing (Sensor harness opening of
back bearing cap should be directly inline with Phase B solder tab) . The ESC’s Extreme Sport
Mode works best with Novak brushless motors set to 30° mechanical timing.
2. INSTALL PINION GEAR & ADJUST MOTOR FOR PROPER GEAR MESH
Tighten pinion’s set screw on flat of motor shaft. Align pinion & spur gears.
A. You NEED a small amount of play between the pinion & spur gear (about
thickness of a piece of paper)–check free play at several points around spur
gear to ensure a proper mesh (Make sure gear mesh is NOT TOO TIGHT).
B. Tighten motor mounting screws–Avoid using excessive force that could
break screws or strip the threaded holes in motor.
3. CHECK FOR PROPER GEARING DURING INITIAL RUNS
The brushless motor & ESC should NOT be hotter than 160°F after a 5 minute
run--Lower the gearing (& check drive train for problems) if temps are higher.
4. CONNECT ESC’s MOTOR POWER PHASE WIRES TO MOTOR
A. Solder the speed control’s Phase ‘A’ silicone motor power wire to the
motor’s Phase “A” solder tab.
B. Solder the ESC’s Phase ‘B’ motor wire to the motor’s Phase “B” solder tab.
C. Solder the ESC’s Phase ‘C’ motor wire to the motor’s Phase “C” solder tab.
5. CONNECT MOTOR SENSOR HARNESS TO ESC
Insert the 6-pin connector of the motor’s sensor harness into ESC’s sensor
harness socket—connector is keyed and only inserts in one direction.
Battery connection
1. CONNECT ESC’S BATTERY CONNECTOR TO BATTERY PACK
Solder the ESC’s RED & BLACK battery power wires to a battery connector,
and connect ESC to a fully charged battery pack.
Use low-loss high power connectors like Dean’s Ultra Plug or Novak Power Connector.
• Use polarized connectors. Reverse voltage will damage ESC & void warranty.
• Use a female connector on battery packs to avoid shorting of exposed contacts.
• Insulate all exposed wiring connections to avoid shorting.
Voltage Cut-Off Circuitry must be turned OFF if using NiMH/NiCd batteries.
External BEC is Recommended for 3-4S Usage with High-Power Servos!
ESC
ON/OFF
Switch
Servo plugged into
steering ch. (Ch.1)
Set
button
Status LEDs
FM
Receiver
Trail excess wire off top
of antenna mast
Novak
sensor-based
brushless motor
Blue motor
phase wire
(Phase A)
Yellow motor
phase wire
(Phase B)
Orange
motor phase wire
(Phase C)
Sensor harness
Red power wire
(battery positive)
Black power wire
(battery negative)
Battery
connector
On-Board
PowerCaps
2S-4S LiPo Battery pack
(ext.BEC recommended for 3-4S & high-power servos)
*Note: Battery pack, servo, and receiver are not included.
For informative installation and how-to videos,
visit the Team Novak Channel on YouTube®.
With at least 2 of the Motor Power Wires disconnected & ESC connected
to a charged battery pack, the receiver, & the motor’s sensor harness:
1. WITH THE ESC OFF, TURN ON THE TRANSMITTER’S POWER
2. PRESS & HOLD ESC’S ONE-TOUCH/SET BUTTON
3. TURN ON THE SPEED CONTROL’S POWER
With transmitter at neutral (still pressing SET button), slide ESC’s switch to ON position.
4. CONTINUE HOLDING SET BUTTON UNTIL RED LED COMES ON
5. RELEASE SET BUTTON AS SOON AS RED LED TURNS ON
6. PULL TRANSMITTER THROTTLE TO FULL-ON POSITION
Hold it there until green status LED turns solid green. (Motor won’t run during programming).
7. PUSH TRANSMITTER THROTTLE TO FULL-BRAKE/REVERSE
Hold it there until the green status LED blinks green.
8. RETURN TRANSMITTER THROTTLE TO NEUTRAL
The red status LED will turn solid red, indicating that speed control is at neutral and
that proper programming has been completed.
If transmitter settings are changed, the One-Touch Programming must be repeated.
If you experience any problems, turn off ESC and repeat One-Touch.
NOTE: One-Touch Programming reverts ESC back to factory-default settings.
STEP 4-one-touch programming
transmitter adjustments
Transmitter adjustments may not be required to properly complete the One-Touch
programming. If you have any problems with the programming, adjust your
transmitter settings as listed below and repeat ONE-TOUCH PROGRAMMING.
THROTTLE CHANNEL ADJUSTMENTS
A. Set HIGH ATV or EPA to 100%. [amount of throw at full throttle]
B. Set LOW ATV, EPA, or ATL to 100%. [amount of throw at full brakes]
C. Set EXPONENTIAL to zero setting. [throttle channel linearity]
D. Set THROTTLE CHANNEL REVERSING SWITCH to either position.
E. Set THROTTLE CHANNEL TRIM to middle. [adjusts neutral position]
F. Set ELECTRONIC TRIGGER THROW to 70% throttle/30% brake (or 7:3)--best for
racing. Set to 50%/50% for full time use with reverse for best performance.
G. Set MECHANICAL TRIGGER THROW to 2/3 throttle and 1/3 brake throw position.
•NOT ALL TRANSMITTERS HAVE ALL OF THESE ADJUSTMENTS•
step 3–connect receiver
receiver connection
The ESC has a user-replaceable input signal
harness with the industry-standard JST
connector on both ends of it.
ESC works with all major brand’s new receivers
(very old receivers need wiring sequence changed
in plastic plug on receiver end-- Damage may
occur if sequence is incorrect). For instructions on
changing the wiring sequences, visit our web site.
1. CONNECT RECEIVER HARNESS TO Rx PINS ON ESC
Insert the JST connector of receiver input harness onto the receiver harness 3-pin
header on the ESC. White wire goes on the left side pin as shown above.
2. CONNECT RECEIVER HARNESS TO RECEIVER
Insert 3-pin connector of receiver harness into Ch.2 (throttle) slot of receiver.
3. INSTALL 25mm COOLING FAN ON ESC (OPTIONAL)
Press fan screws through 2 of the holes along one edge of the fan and into the 1st
gap of ESC heat sink fins. Plug fan connector onto ESC’s fan pins--note polarity.
4. CONNECT GLITCH BUSTER CAPACITOR TO RECEIVER (OPTIONAL)
The Glitch Buster helps provide reserve power when using the built-in BEC with power
hungy servos. Insert JST connector into any open slot of receiver--note polarity.
set-up photo
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Glitch Buster
capacitor
user-replaceable
input signal harness
(Ch.2)