Novak Digi-Peak (55-3085-1.5) - Manual

set-up guide proper gearing
Motor operating temperature is the ONLY
way to properly set vehicle gearing
Motor & ESC temperatures should NEVER exceed
160°F MAX at any time during operation !
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 that will not be covered by the product’s warranty.
Because of the potential of damage from overheating that can cause ESC or
motor failure, you should start with small pinion sizes and check the
speed control and motor operating temperatures at during the initial runs
after installation. This is the best way to avoid 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 should continually monitor
ESC & motor temperatures to protect your electronics from damage.
This speed control features Novak’s Smart-Stop Dual Voltage Cut-Off Circuitry
built-in, and when used properly will allow you to safely use LiPo batteries,
without letting the cells in either battery pack drop below their critical safety
voltage during operation that results in premature battery failure.
The default ESC setting is that the Voltage Cut-Off is turned ON and is set to
LiPo. If using NiMH cells, you need to switch the Voltage Cut-Off feature OFF.
Yellow status LED will remain ON at all times during operation
to indicate that the LiPo Voltage Cut-Off Circuity is turned ON.
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 batteries.
Reaching critical safety voltage too many times can damage the cells.
Note: Whenever the speed control’s One-Touch Programming is
performed, this setting will revert to the LiPo default setting.
DO NOT USE LiPo BATTERIES WITH THE
VOLTAGE CUT-OFF CIRCUITRY TURNED OFF
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.
voltage cut-off circuitry
temperature monitoring
This speed control has a built-in diagnostic temperature monitoring feature
that lets you quickly and easily check the ESC’s operating temperature at any
time with a click of the ESC’s push-button.
While connected to a battery and powered ON,
simply tap the ESC’s SET
button and one of the on-board LED lights will flash 4 times to indicate the
operating temperature of the speed control:
WHITE flashing LED = normal operating temp-- under 135°F (57°C).
BLUE flashing LED = medium operating temp-- 136-147°F (58-64°C).
YELLOW flashing LED = hot operating temp-- 148-167°F (65-75°C).
GREEN flashing LED = hotter operating temp-- 168-194°F (76-90°C).
RED flashing LED = hottest operating temp--195-215°F (91-102°C).
You are now pushing the ESC extremely hard and should be very
careful to avoid overheating and possible thermal shut-down.
All LEDs flashing = DANGEROUS operating temp-- 216-239°F (103-115°C).
Your ESC is now about to thermally shut-down.
Reduce the pinion size/check drive train to avoid ESC
overheating that could result in potential damage.
NOVAK R/C, INC.
19 Rancho Circle, Lake Forest, CA 92630
PHONE: (949) 916-6044 • Monday-Thursday
Customer Service E-mail: [email protected]
#55-3085-1.5
1-2014
SPECIFICATIONS
Input Voltage .......................... Dual 2S LiPo or Dual 6-cell NiMH packs
Brushless Motor Limit ...............................Novak Diablo 550 Sensored
ESC Size .........................1.16” x 1.47” x 0.97”H (29.5 x 37.3 x 24.6mm)
ESC Weight (w/o wires) ..................................1.29 ounce (36.6 grams)
B.E.C. Voltage/Current (built-in) ......................6.0 volts DC / 3.0 amps
Power Wire (Battery/Motor) ............................. 14G Super-Flex Silicone
On-Resistance .................................... 0.0004 ohm (@25°C trans.temp.)
Drive Modes (1 of 3) ............... Partial Reverse, Standard, Limited Output
LiPo Voltage Cut-Off (1 of 2) ...................................................ON/OFF
Launch Limit/Acceleration Ramp (1 of 2) .................................ON/OFF
Diablo 550 Motor Size ....................... 1.41”D x 2.84”L (35.8 x 72.1mm)
Diablo 550 Motor Weight (w/o wires) ..........10.1 ounce (286.3 grams)
Diablo 550 Motor Shaft Size ....................................................... 5mm
PLUG-IN INPUT SIGNAL HARNESS (MINI-JST) [Novak kits #5304 & #5309]
Input signal harness with 2mm Mini plug on ESC end--4.5” (#5304), 9” (#5309).
BATTERY HARNESS WITH TRAXXAS® CONNECTOR [Novak kit #5331]
Flexible 14GA red and black silcone power wire with Traxxas® battery connector.
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).
5-AMP UNIVERSAL BEC (For 2S LiPo) [Novak kit #5465]
Supplies 6.0V / 5A of power to receiver & servo for extra BEC performance on 2S LiPo.
SUPER-FLEX SILICONE 14GA WIRE SET [Novak kit #5508]
Two each of 9” length black, red, blue, yellow, and orange 14GA wire.
REPLACEMENT ESC SWITCH HARNESS [Novak kit #5600]
Replacement ON/OFF switch harness for Novak speed controls.
GLITCH BUSTER CAPACITOR [Novak kit #5626]
Supplies reserve power to receiver during spikes of heavy load to avoid drop-out.
REPLACEMENT 25x25x10mm BLACK COOLING FAN--Mini [Novak kit #5649]
Replacement cooling fan with 2mm mini plug harness to fit Novak speed controls.
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).
ACCESSORIES
The Diablo ESC is designed for use with the Novak Diablo 550 sensor-based
brushless motor in dual-battery vehicles like the Traxxas® E-Maxx™.
The Diablo ESC has 3 Drive Modes including a limited power output
mode that is perfect for teaching friends and family to drive.
Features also include Novak’s Launch Limit™ for smooth & controlled
acceleration, Bash Boost™ for blasts of lightning-fast speeds when
you’re pulling full-throttle, plus there is Thermal Overload Protection
& On-Board Temperature Monitoring to keep things in check.
WATER & ELECTRONICS DON’T MIX!
Allowing water, moisture, or other foreign materials to get inside the
speed control will void product’s 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 Novak Diablo 550-size sensor-based brushless motor.
DO NOT FREE REV OR OPERATE WITHOUT LOAD!
This includes running motor without a pinion or holding car in the air and
running motor at or close to full power. Free revving will void the warranty!
NO SCHOTTKY DIODES!
Do not use Schottky diodes with with reversible ESCs!
DUAL 2S LiPo OR 6 CELL NiMH PACKS ONLY
NEVER exceed 2S LiPo packs--Be sure Voltage Cut-Off option is turned ON.
YOU MUST USE 2 BATTERIES--ESC WILL NOT OPERATE ON A SINGLE PACK
UNPLUG BATTERIES WHEN NOT IN USE & SWITCH ESC OFF
Always disconnect batteries from ESC to avoid short circuits & possible fire hazard.
ALWAYS SWITCH OFF ESC BEFORE CONNECTING BATTERIES
If batteries are connected with ESC switch in ON position, serious damage can occur.
POWERCAP REQUIRED
An external PowerCap is installed on the ESC & MUST be used at all
times. Failure to use the correct Novak PowerCap will result in higher ESC
temperatures & possible damage.
GOOD QUALITY LiPo BATTERIES SUGGESTED
Using low quality LiPo batteries that cannot supply the amperage
required by this system will result in possible battery, ESC, & motor
damage, and will void the warranty.
TRANSMITTER ON FIRST
Always turn on transmitter power first so you will have control of
vehicle when you turn the ESC’s power on.
GOOD QUALITY RADIO SYSTEM 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.
DO NOT BUNDLE POWER & SIGNAL WIRES TOGETHER
RF noise in the power wires can adversely effect radio system performance.
INSULATE WIRES & NO REVERSE VOLTAGE!
Insulate exposed wiring with heat shrink tubing or electrical tape to prevent
shorts. Never reverse connect battery--ESC damage will occur & void warranty.
NO CA GLUE
CA glue or its fumes can damage the PC board and internal
components of the ESC & cause premature failure.
PRECAUTIONS
trouble-shooting guide
Steering Channel Works But Motor Will Not Run
• Possible receiver damage––Check operation with a different receiver.
• Possible internal damage––Refer to ‘SERVICE PROCEDURES’ section.
• Check motor or motor connections.
• Check ESC is plugged into receiver’s throttle channel. Check signal harness wire sequence.
Receiver Glitches/Throttle Stutters During Acceleration
• Receiver or antenna too close to ESC, power wires, battery, or motor.
• Bad motor sensors, sensor harness, or connections––Check wiring, sensor harness, &
connections, perform hall sensor test (Refer to ‘MOTOR HALL SENSOR TEST’ section).
• Low voltage to receiver––Try Novak Glitch Buster (#5626) on receiver to retain power.
• PowerCap damaged/missing––Replace PowerCap/Trans-Cap Module.
• Battery pack damaged or weak––Try a different battery pack.
• Motor magnet weak or overheated––Replace rotor (Refer to motor manufacturer’s website).
• Excessive current to motor—Use a milder motor or a smaller pinion gear.
• Untidy wires or signal and power wired bundled together. Input harness and servo
wires should be bundled separately. Power wires should be as short as possible.
Motor and Steering Servo Do Not Work
• Check wires, receiver signal harness wiring & color sequence, radio system, crystals,
battery/motor connectors, & battery pack.
• Possible receiver damage––Check operation with a different receiver.
• Possible internal damage––Refer to Service Procedures.
Motor Runs Backward
• Reverse motor rotation direction––Refer to ‘CUSTOM PROGRAMMING OPTIONS’ section.
• Improper One-Touch set up––Refer to ‘ONE-TOUCH PROGRAMMING’ section.
Speed Control Runs Excessively Hot
• Gear ratio too low––Increase gear ratio/Reduce pinion (refer to ‘PROPER GEAR SELECTION’).
• Motor is damaged––Try a different motor.
Model Runs Slowly/Slow Acceleration
• Gear ratio too high––Reduce gear ratio/Increase pinion (refer to ‘PROPER GEAR SELECTION’).
• Check battery & connectors––Check battery pack & connectors. Replace if needed.
• Incorrect transmitter/ESC adjustment––Refer to ‘TRANSMITTER ADJUSTMENTS’.
• PowerCap damaged/missing––Replace PowerCap or Power Trans-Cap Module.
ESC Is Melted Or Burnt/ESC Runs With Switch Off
• Internal damage––Refer to Service Procedures.
No Power to the BEC
• Check power wire connections to your battery, ESC and BEC unit.
• Check BEC input harness is plugged into receiver & ESC’s red wire is removed from harness.
• Be sure that the BEC unit switch is turned ON.
error/LED codes
• Yellow status LED on solid at neutral––LiPo Voltage Cut-Off feature is turned ON.
• Red & Green status LEDs on solid––Check input signal harness connections at ESC and
receiver. Check input signal harness wiring sequence––Refer to STEP 3.
• Red status LED on solid & Green LED blinking––Check motor sensor harness connection.
Possible internal motor damage.
• Blue & Green status LEDs both blinking. Misfire shut-down––return throttle to neutral
position to regain motor control––check drive train for free operation.
• Blue & Red status LEDs blinking. Possible ESC thermal shut-down––Check gear ratio
& free operation of drive train for possible overloading/ESC is being severely over-
loaded––allow system to cool & return throttle to neutral position to regain motor
control. LEDs will continue to blink until system is cooled down.
• Blue & Yellow status LEDs blinking. Possible Motor thermal shut-down––Check gear
ratio & free operation of drive train for possible overloading/Motor is being severely
over-loaded––allow system to cool & return throttle to neutral position to regain
motor control. LEDs will continue to blink until system is cooled down.
• Blue & Green (Misfire Detection), Blue & Red (ESC Thermal Shut-Down), or Blue &
Yellow (Motor Thermal Shut-Down) status LEDs blinking. ESC may have shut-down &
ESC’s neutral point is too far off to sense that transmitter throttle has been returned
to neutral (Refer to ‘ONE-TOUCH’ & ‘TRANSMITTER ADJUSTMENTS’).
• Red & Green status LEDs toggling. LiPo/LiFe Cut-Off voltage reached. Recharge battery.
service procedures
Before sending your product in for service, review the Trouble-Shooting Guide. Product
may appear to have failed when other problems exist. After reviewing instructions, if you
feel that you require service, obtain the most current service options & pricing as follows:
WEB: Print out the
PRODUCT SERVICE FORM from CUSTOMER SERVICE section of the web
site. Fill out required information on form and return it with the product requiring service.
WARRANTY SERVICE: You MUST CLAIM WARRANTY on
PRODUCT SERVICE FORM & include
a valid cash register receipt with purchase date, dealer name, & phone# on it, or a previous
service invoice. If warranty provisions have been voided, there will be service charges.
• ESCs returned without a serial number will not be serviced under warranty •
TRADE-IN PROGRAM: Novak offers a trade-in program for non-warranty items toward
current and discontinued products. You can replace, exchange, or upgrade Novak products
as listed within the trade-in program. Complete a Non-Warranty Service Form to be eligible.
ADDITIONAL NOTES:
• Dealers/distributors aren’t authorized to replace products thought to be defective.
• If a hobby dealer returns your product for service, submit a completed PRODUCT
SERVICE FORM to the dealer and make sure it is included with product.
• Novak R/C, Inc. does not make any internal electronic components (transistors,
resistors, etc.) available for sale.
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 6 cells (1.2 volts DC/cell) or more than 2 LiPo cells input voltage, 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 Diablo motor or a non-sensored motor,
operating ESC without factory-installed PowerCaps or operating with damaged PowerCaps, using a Schottky
diode, splices to input 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 Electronics, Inc. Diablo Brushless ESC, Launch Limit, Thermal Overload
Protection, Hall Sensor Test, & One-Touch Set-Up are all trademarks of Novak R/C, Inc.