Novak Havoc Sport ESC Custom Programming & Gearing Guide (55-1735-1) - Manual (Page 2)

FIGURE 1
User-replaceable input harness
plugged into the Novak’s XXtra
Synthesized FM Receiver: 75 Mhz.
P3 P2
Green
LED
STEP 3 –
STEP 1 – CONNECT INPUT HARNESS
WIRE SPEED CONTROL TO
MOTOR
(REFER TO FIG. 2)
USING A RECEIVER BATTERy PACk
Steering Channel Works but Motor Will Not Run
• Red status LED blinking when throttle is applied. Check motor sensor harness
connection at ESC (make sure all metal sockets are fully inserted into the connector’s
plastic housing)––check for damaged wires.
• Red status LED on solid & Green LED blinking. Check input signal harness & motor
sensor harness connections at ESC. Check input signal harness wiring sequence &
connection at throttle channel of receiver. Check throttle channel operation with servo.
• blue & Green status LEDs both blinking. Possible ESC shut-down due to locked rotor
detection––return throttle to neutral position to regain motor control––check vehicle’s
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 & Amber status LEDs blinking. Possible motor thermal shut-down––Check gear
ratio & free operation of drive train for possible overloading/motor is being 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 (Locked Rotor Detection), blue & Red (ESC Thermal Shut-Down), or blue
& Amber (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 (see Steps 5 & 6).
• Red & Green status LEDs toggling. Li-Po/Li-Fe Safety Cut-Off voltage reached. Remove
and charge / replace battery pack.
• Possible receiver damage––Check operation with a different receiver.
• Possible internal damage––Refer to Service Procedures.
Receiver Glitches/Throttle Stutters During Acceleration
• Receiver or antenna too close to ESC, power wires, battery, or motor.
• Bad connections––Check wiring, connectors, & sensor harness.
• External Power Trans-Cap Module damaged/not installed––Replace with Novak #5679.
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.
Speed Control Runs Excessively hot
• Gear ratio too low––Increase gear ratio and check Power Trans-Cap Module (see Step 3).
Model Runs Slowly/Slow Acceleration
• Gear ratio too high––Reduce gear ratio (see Step 3).
• Check battery connectors––Replace if needed (see Step 4).
• Incorrect transmitter/ESC adjustment (see Steps 5 & 6).
• External Power Trans Cap Module damaged/not installed––Replace with #5679.
ESC Is Melted Or burnt/ESC Runs With Switch Off
• Internal damage––Refer to Service Procedures.
*Check Novak’s Web site for additional information.
TROUBLE-SHOOTING GUIDE
SERVICE PROCEDURES
Before sending your speed control or brushless motor system in for
service, review Trouble-Shooting Guide and all instructions. System
may appear to have failed when other problems exist.
After reviewing instructions, if you feel that your ESC/system requires
service, please obtain the most current product service options and
pricing by the following ways:
WEb SITE: Print a copy of the PRODUCT SERVICE FORM from the CUSTOMER SERVICE
section of the Web site. Fill out the needed information on this form and return it with
the Novak product that requires servicing.
PHONE/fAX: If you do not have access to the internet, please contact our customer
service department by phone or fax as listed below.
WARRANTy SERvICE:
For warranty work, you MUST CLAIM WARRANTY on
PRODUCT SERVICE FORM & include a valid cash register receipt with purchase date and
dealer name & phone# on it, or an invoice from previous service. If warranty provisions
have been voided, there will be service charges.
•ESCs returned without a serial number will not be serviced under warranty•
ADDITIONAL NOTES:
• Units that operate normally will have a service charge.
• Dealers/distributors are not authorized to replace Novak products thought to be defective.
• If a hobby dealer returns your brushless system for service, submit a completed PRODUCT
SERVICE FORM to the dealer and make sure it is included with the product.
• Novak does not make any internal electronic components available for sale.
NOvAK ELECTRONICS, INC.
PHONE: (949) 833-8873
FAX: (949) 833-1631
Customer Service e-mail: [email protected]
Mount the speed control so that the power wires are as far away from other electronics
as possible. Make sure that the speed control or the power wires will not interfere with
any moving parts in the vehicle. Select a location that has good cooling and allows
airflow through heat sinks.
If the ESC gets air flow, it will run cooler; and that means it will be more efficient!
1. MOuNT SpEED CONTROL IN vEhICLE
Use the included double-sided tape to mount the speed control in vehicle (do not use
glue). Avoid contact with side walls or other chassis components to avoid vibration damage.
be sure receiver & antenna are mounted as far from ESC, power wires, battery, &
servo as possible--these components all emit Rf noise when throttle is applied. On
graphite or aluminum chassis vehicles, it may help to place receiver on edge with
crystal & antenna as far above chassis as possible.
Note: Mount antenna as close to receiver as possible – trail any excess wire off top of
antenna mast (cutting or coiling excess antenna wire will reduce radio range).
2. SECuRE pOWER TRANS-CAp MODuLE TO ChASSIS
Use the included double-sided tape to mount Power Trans-Cap Module to the
vehicle’s chassis. Module can also be tie-wrapped along the power wires–This requires
less space on the chassis and provides good isolation from vibration.
3. INSTALL ON/Off SWITCh
Using the included double-sided tape, mount the switch where it will be easy to
access–Be sure to select a position where it will not get damaged or get switched
OFF during a crash or roll-over.
With ESC connected to (at least) a receiver & a charged battery pack:
1. TURN ON THE TRANSMITTER’S POWER
2. PRESS & HOLD ESC’S ONE-TOUCH/PROGRAMMING BUTTON
Note: The Havoc Pro’s One-Touch/Programming button is combined with
the ON/OFF switch on the Remote Power Programming Switch harness.
3. TURN ON THE SPEED CONTROL’S POWER
With transmitter throttle at neutral, and still pressing the One-Touch
button, slide the ESC’s ON/OFF switch to ON position.
4. CONTINUE HOLDING BUTTON UNTIL RED LED COMES ON
5. RELEASE ONE-TOUCH BUTTON AS SOON AS LED TURNS RED
6. PULL TRANSMITTER THROTTLE TO FULL-ON POSITION
Hold it there until the green status LED turns solid green.
Note: Motor will not run during programming even if connected.
7. PUSH TRANSMITTER THROTTLE TO FULL-BRAkES
Hold it there until the green status LED blinks green.
8. RETURN TRANSMITTER THROTTLE TO NEUTRAL
Red status LED will turn solid red, indicating that speed control is
at neutral and that proper programming has been completed.
NOTE: If transmitter settings are changed, One-Touch Programming
must be repeated. If you experience any problems, turn off ESC &
repeat One-Touch. Whenever One-Touch set-up is performed, ESC
automatically reverts to factory default settings.
The Havoc Pro ESC is compatible with all Novak 540-sized brushless sensored
motors. It is not compatible with brushed or sensorless brushless motors.
1. ChECK fOR pROpER GEARING
Neither the brushless motor (with sintered rotor) nor the ESC should be
hotter than 160°F after a 5 min. run. If either temperature is higher, the
gearing should be lowered until both the ESC and the motor are under this
temperature. The cooler the ESC runs, the better the performance of the system.
2. SOLDER MOTOR pOWER phASE WIRES TO MOTOR
If you purchased a Havoc Pro brushless System, your motor is factory-wired
to a ballistic brushless Motor. Skip to STEP 4.
A. Cut the ESC’s bLUE, YELLOW & ORANGE silicone motor power wires
to the desired length, and strip 1/8-1/4” of insulation from the end of
each wire. Tightly twist the exposed strands of wire.
B. Place the ESC’s bLUE Phase ‘A’ motor wire onto motor’s ‘A’ solder tab
& solder. Use a soldering iron to apply heat to exposed wire; begin
adding solder to tip of soldering iron & to wire. Add just enough solder
to form a clean & continuous joint from the plated area of the solder
tab up onto the wire. Use side cutters to trim remaining (now soldered)
wire extending beyond the solder tab (about 1/16” above PCB).
IMPORTANT NOTE: DO NOT OVERHEAT SOLDER TABS
Prolonged/excessive heating of solder tabs (motor or ESC) will damage PCB.
C. Solder the ESC’s YELLOW Phase ‘b’ motor wire to the motor’s ‘b’ solder
tab as described in Step 2B above.
D. Solder the ESC’s ORANGE Phase ‘C’ motor wire to the motor’s ‘C’ solder
tab as described in Step 2B above.
Note: Make sure no wire strands have strayed to an adjacent solder tab, this
will result in short-circuiting & severe ESC damage, which will void the warranty.
3. CONNECT MOTOR SENSOR hARNESS TO ESC
Insert the 6-pin connector on the end of the motor’s sensor wires into
ESC’s sensor harness socket–the connector is keyed and will only go in,
in one direction.
pOWER TRANS-CAp MODuLE REQuIRED
The factory-installed Power Trans-Cap Module MUST be used with brushless motors.
If Power Trans-Cap Module becomes dented or damaged, ESC failure can occur–replace
immediately (Novak kit #5679). Longer Power Capacitor wires will decrease performance.
DO NOT uSE SChOTTKy DIODES
Schottky diodes must NOT be used with reversible ESCs. Schottky diode usage will
damage the ESC & void warranty.
MOTOR CApACITORS NOT NEEDED
Novak brushless motors do not require external motor capacitors.
h
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OTO
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RE 2)
The Havoc Pro has a user-replaceable
input harness with the industry-standard
receiver connector on it & works with
all major radio brand’s new receivers
[Refer to Figure 1 to see how to connect
the included user-replaceable input
harness to Novak’s XXtra Synthesized FM
Receiver: 75 Mhz (#S2675N)]. However,
some very old receivers must have the
wiring sequence in the plastic 3-pin
JST connector housing changed on
the receiver end. This is important, as
the receiver & servo electronics may be
damaged if the sequence is incorrect.
for instructions on changing the wiring
sequence for older receivers, visit the
Novak Web site (www.teamnovak.com).
STEP 2
–
MOUNT ESC
If you are planning to use an external receiver battery pack to power the
electronics you need to do the following:
1. Plug the external 5 cell (1.2VDC/cell) receiver battery pack into the
battery slot of the receiver.
2. To turn the vehicle ON, switch the receiver pack ON. Then, turn the
ESC’s switch ON, then OFF to allow the ESC to be powered by an
external source.
3. To turn the vehicle OFF, turn the receiver pack’s switch OFF.
ALTERNATIVE METHOD
1. Plug the external 5 cell (1.2 VDC/Cell) receiver battery pack into the
battery slot of the receiver.
2. Unplug the ESC’s red wire from the input harness going to the
receiver. Insulate the red wire to keep it from shorting.
3. To turn the vehicle ON, switch the receiver pack ON. Then, turn the
ESC’s switch ON.
4. To turn the vehicle OFF, turn the ESC’s switch OFF. Then, turn the
receiver pack’s switch OFF.
STEP 6
–ONE-TOUCH PROGRAMMING
For proper ESC operation, adjust transmitter as follows:
A. Set HIGH ATV or EPA to maximum setting.
[amount of throw at full throttle]
B. Set LOW ATV, EPA or ATL to maximum setting.
[amount of throw at full brakes]
C. Set EXPONENTIAL to zero setting. [throttle channel linearity]
D. Set THROTTLE CHANNEL REV. SWITCH to either position.
E. Set THROTTLE CHANNEL TRIM to middle setting.
[adjusts neutral position/increases or decreases coast brakes]
F. Set ELECTRONIC TRIGGER THROW ADJUSTMENT to 70% throttle
and 30% brake throw (or 7:3) for forward & brake only Profiles,
and 50% throttle and 50% brake throw (or 5:5) for Profiles with
reverse.
[adjusts trigger throw electronic/digital pistol-grip transmitters]
G. Set MECHANICAL TRIGGER THROW ADJUSTMENT (if radio has it)
to position with 2/3 throttle and 1/3 brake throw for forward &
brake only Profiles, and position with 1/2 throttle and 1/2 brake
throw for Profiles with Reverse.
[adjusts trigger throw on mechanical/analog pistol-grip transmitters]
•NOT ALL TRANSMITTERS HA
VE THESE ADJUSTMENTS•
STEP 5
–
TRANSMITTER ADJUSTMENTS
ON/OFF
Switch
Servo plugged into
steering ch. (#1)
2-cell Li-Po batter
y pack
Red power wire
(battery positive)
Black power wire
(battery negative)
Battery
connector
Novak
sensor-based
brushless
motor
Power Trans-
Cap Module
(Novak #5679)
A B C
Sensor harness
Cooling Fan
(required)
XXtra Synthesized
FM Receiver
(Novak #S2675N)
User-replaceable
input signal
harness (Ch.2)
Motor power wires
Blue – Phase A
Yellow – Phase B
Orange – Phase C
Trail excess wire off top of antenna mast
bRuShLESS MOTOR pRECAuTIONS
To connect the Havoc Pro to the battery pack using connectors, we suggest
low-loss, high power connectors like Novak’s Power Connectors (Novak
#5731) or Dean’s Ultra.
• Use polarized connectors. Reverse voltage will damage ESC & void warranty.
• Use a female connector on battery packs to avoid shorting.
1. INSTALL bATTERy CONNECTOR
A. Cut the RED & bLACK silicone battery power wire to the desired length,
and strip 1/8”–3/16” of insulation from the end of each wire. Tightly
twist and tin the ends of the exposed wire with solder.
B. Solder the ESC’s RED (+) battery wire to the connector’s POSITIVE (+) contact.
C. Solder the ESC’s bLACK (–) battery wire to the connector’s NEGATIVE (–) contact.
D. Cover the exposed solder joints with heat shrink tubing to prevent
possible short circuits.
2. CONNECT ESC TO bATTERy pACK
Connect the speed control’s battery connector to a fully charged 2S Li-
Po, 2S Li-Fe or 4-6 Ni-MH cells (1.2 VDC/cell) battery pack.
NOTE: If using Ni-MH, the Li-Po Cut-Off Circuitry must be deactivated.
If using Li-fe batteries, the cut-off voltage must be changed.
Refer to page 4 for further customizing options.
STEP 4
– WIRE SPEED CONTROL TO
BATTERy
(REFER TO FIG. 2)
One-Touch
Set-Up Button
Motor
Turns
Touring
Car
2wd
Buggy
2wd
Truck
4wd
Buggy
1/12-Scale Oval
3.5 10.5 Not Rec. Not Rec. Not Rec. 1.1”/28mm 1.2”/31mm
6.5 7.5 10 11.5 10 1.4”/35mm 1.5”/38mm
10.5 5.5 8 9.5 8 2”/51mm 2.6”/66mm
13.5 4.5 7 8.5 7 2.3”/58mm 2.9”/73.5mm
17.5 3.75 6 7.5 6 2.56”/65mm 3.23”/82mm
w w w . t e a m n o v a k . c o m