BASIC SET-UP GUIDE
––– crusher
• Download “ESC Field Guide” from our web site for Proper Gearing & Custom Programming • Read All Instructions Before Use •
PRECAUTIONS
WATER & ELECTRONICS DON’T MIX!
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.
the sensor harness connector is directly in-line with the center (Phase B) solder tab.
--Ext.BEC Recommended w/Heavy Servo Loading
(refer to Field Guide)
RF noise in the power wires can adversely effect radio system performance.
(with the proper turn motors only!)
. For NiCd/NiMH, disable the Voltage Cut-Off circuitry.
--Be sure Voltage Cut-Off option
TRANSMITTER ON FIRST
INSULATE WIRES & NO REVERSE VOLTAGE!
& never reverse connect the battery--ESC damage will occur & void warranty.
NO CA GLUE
Re-charge battery after Smart-Stop circuitry shuts off throttle
Reaching critical safety voltage too many times can damage the cells.
(after a short resting period)
to a level high
#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)
•
ACCESSORIES
PLUG-IN INPUT SIGNAL HARNESS (JST-JST)
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).
3
A 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]
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).
[Novak kits #5315 & #5320]
*HIGHLY RECOMMENDED*
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.
Allowing water, moisture or other foreign materials to get inside ESC will void warranty.
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
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
NEVER exceed 4S LiPo packs
is turned ON
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
DISCONNECT MOTOR BEFORE BINDING or ONE-TOUCH
Motor may receive full throttle signal if connected to ESC & damage or injury can occur.
Turn on transmitter power first so you will have control of vehicle when you turn it on.
Insulate exposed wiring with heat shrink tubing or electrical tape to prevent short circuits,
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.
CA glue or fumes can damage internal components of ESC & cause premature failure.
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.
Even though the pack’s voltage will rise
enough to run motor again, this is not good for LiPo or LiFe batteries.
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.
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
3.
SECURE POWER WIRES TO AVOID DAMAGE
--select a place where it will not get damaged/switched OFF in a crash
.
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.
step 2–connect motor/battery
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
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.
• 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!
Reverse voltage will damage ESC & void warranty.
(about
.
step 3–connect receiver
receiver connection
The ESC has a user-replaceable input signal
ha rne ss wi th th e indu stry -st and ard 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).
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.
For instructions on
status
LEDs
negative fan wire
positive fan wire
black wire
(Rx negative)
white wire
one-touch
button
red wire
(Rx positive)
(Rx signal)
STEP 4-one-touch programming
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.
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.
(Motor won’t run during 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•
motor phase wire
Yellow motor
phase wire
(Phase B)
Novak
sensor-based
brushless motor
(ext.BEC recommended for 3-4S & high-power servos)
Sensor harness
2S-4S LiPo Battery pack
set-up photo
Orange
(Phase C)
Blue motor
phase wire
connector
(Phase A)
Battery
ESC
ON/OFF
Switch
Black power wire
(battery negative)
Red power wire
(battery positive)
Set
button
Status LEDs
For informative installation and how-to videos,
visit the Team Novak Channel on YouTube®.
user-replaceable
input signal harness
(Ch.2)
Servo plugged into
steering ch. (Ch.1)
FM
Receiver
On-Board
PowerCaps
*Note: Battery pack, servo, and receiver are not included.
Trail excess wire off top
Glitch Buster
capacitor
of antenna mast
ww w.t ea mno va k.com
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