Novak EXPLORER SPORT OPERATING INSTRUCTIONS

OPERATING INSTRUCTIONS

INTRODUCING

THE

EXPLORER

SPECIFICATIONS

PART #1900

EXPLORER ACCESSORIES

BRAKE LIGHT KIT

The Explorer Sport speed control comes equipped with
built in circuitry to power two high power brake light
LEDs. Novak's optional Brake Light Kit (#5655) comes
complete with two premium quality LEDs and versatile
mounting brackets to mount the brake lights behind the
taillight section of the car body or onto most any vertical
or horizontal surface on the chassis.

MOTOR CAPACITORS

To prevent radio interference problems, you must have
three 0.1µF capacitors properly installed on every motor.
Included with the Explorer Sport speed control are three

0.1µF (50V) capacitors for one motor. Additional 0.1µF
(50V) capacitors are also available in Novak kit #5620.
Please refer to Step 4 on the back page for proper motor
capacitor installation instructions.

COOLING FAN

An optional ESC Cooling Fan (kit #5645) is available for
use with the Explorer ESC to provide extra cooling for
heavy load applications with limited air circulation. If the
ESC gets so hot that it goes into thermal protection
mode, we recommend using the optional Cooling Fan.

The Novak Explorer Sport ventures to bring race winning
high frequency design to the economical price range of
the sport level ESC (Electronic Speed Control). Equipped
with Novak's revolutionary Polar Drive Technology™ the
Explorer runs faster and longer than conventional speed
controls. The Polar Drive circuitry provides smooth throttle
response and improved radio system performance. The
Explorer also has built-in brake light circuitry to power two
external LEDs for added realism with Formula One and
touring cars. (Two high power brake LEDs and versatile

mounting hardware are available in Novak kit #5655)

Novak's Solid State RVP™ provides rugged protection
against reverse voltage application without the need for
fuses, while the built-in BEC (Battery Eliminator Circuit)
powers the radio system with no external receiver battery.

Other features include the Novak Input Plug System™ for
compatibility with all major radio systems, and purple
anodized Micro Fin™ heat sinks. While factory installed
JST/Tamiya style battery connectors and bullet style motor
connectors make for quick and easy installation of the
speed control into your car or truck.

PRECAUTIONS

• READ INSTRUCTIONS CAREFULLY BEFORE USING!

• WATER & ELECTRONICS DON'T MIX! Do not operate
model in or around water. Never allow water, moisture,
or other foreign materials to get inside the ESC.

• 6 OR 7 CELLS ONLY Never use more than 7 or less than
6 sub-C cells (1.2 volt DC/cell) in the main battery pack.

• MOTOR CAPACITORS REQUIRED Three 0.1µF (50V)
ceramic capacitors must be properly installed on every
motor to prevent radio interference.

• DON'T LET TRANSISTOR TABS TOUCH Never allow the
two transistor tab banks or the heat sinks to touch each
other or any exposed metal, as this will create a short
circuit and damage the speed control.

• DISCONNECT THE BATTERIES Always disconnect the
battery pack from the speed control when not in use.

• TRANSMITTER ON FIRST Always turn on the power of
your transmitter first so that you will have control of the
radio equipment when you turn on the speed control.

• DON'T GET BURNT! Transistor tabs can get hot, so be
careful not to touch them until they cool.

• INSULATE WIRES Always insulate exposed wiring with
heat shrink tubing to prevent short circuits.

Input Voltage 6-7 cells (1.2 volts DC/cell)
Case Width 1.98 inches [50.29 mm]
Case Depth 1.42 inches [36.07 mm]
Case Height 0.70 inch [17.78 mm]
Weight (w/o heat sinks) 1.87 ounces [50.01 g]
On-Resistance @ Transistors 0.005 Ω
Rated Current 150 amps
Braking Current 50 amps
BEC Voltage 5.0 volts DC
BEC Current 0.5 amps
Wire Size (Battery/Motor) 16 gauge
Wire Length
Signal Harness Length 6 inches [152 mm]
Transistor Type MEGAFET
PWM Frequency 2500 hertz (nominal)
Part Number 1900
Brake Light Part Number 5655 (optional accessory kit)

(Battery/Motor)

6 inches [152 mm]

@ 25°C transistor

junction temp.

RADIO INTERFERENCE

The high frequency switching operation of electronic
speed controls can generate radio interference. Here are
some common causes of radio interference problems:

• CAPACITORS NOT INSTALLED ON MOTOR Electric
motors generate radio noise that can interfere with the
receiver. To prevent radio problems, every motor must
have three 0.1µF (50V) ceramic capacitors installed on
it. Refer to Step 4 on back page for proper installation.

• RECEIVER/ANTENNA INCORRECTLY MOUNTED The
receiver and antenna should be mounted as far from
the motor, power wires, battery, and servo as possible,
as these components all emit radio noise. On graphite
or aluminum, place receiver on edge with the crystal
and antenna as far above the chassis as possible. Mount
the antenna close to receiver and trail any excess wire
off the top of antenna. Do not cut or coil excess wire!

• MOTOR BRUSHES WORN As motor brushes continue
to wear, excessive motor noise will be generated. To
avoid radio interference, worn motor brushes should
be replaced. The motor commutator may also need to
be cleaned or trued and can be machined to help the
motor run more efficiently.

STEP 1

CHANGING THE INPUT HARNESS

Included with the Explorer Sport is the Novak Input Plug
SystemTM to convert the Futaba J style signal harness to
be compatible with Airtronics, KO, Kyosho, JR, and Hitec
radios. Refer to Figures 1 through 3 to change plug.

Airtronics (A) KO Kyosho (KYO) JR/Hitec

FIGURE 1 With a small standard screwdriver, press on

each of the three metal prongs until the wires are easy to
remove. Remove wires.

FIGURE 2 With the screwdriver, carefully lift up each of the
metal locking tabs to the angle shown.

STEP 2

HEAT SINK INSTALLATION

Two Micro Fin™ heat sinks have been included to provide
proper cooling for the Explorer Sport. The speed control
will operate cooler and run faster when the heat sinks are
installed. DO NOT use the Explorer without the heat sinks,
as this voids the warranty and may cause speed control to
overheat and thermally shut-down.

1. INSTALL THE LEFT HEAT SINK

Place the speed control on a flat surface and press one
heat sink (longer fins go down onto transistor tabs)
onto the left bank of 3 transistor tabs.

NOTE: Do not use too much force when installing the
heat sinks because you can damage the transistors or other
components on the PC board. Never use a vise or pliers to
install the heat sinks.

2. INSTALL THE RIGHT HEAT SINK

Press the second heat sink (again long fins down) onto
the right bank of 3 transistors tabs.

The heat sinks should press onto the transistor tabs with a
snug fit. If heat sinks are installed upside-down or shifted
off-center, they will be too loose and will not work properly.

3. DO NOT USE GLUE

Do not use glue or other types of adhesives to attach
the heat sinks to the transistor tabs.

4. DO NOT SHORT CIRCUIT HEAT SINKS

The two separate banks of transistor tabs or heat sinks
should never contact each other or other conductive
objects (metal, graphite, etc.), or they will short circuit
and damage the speed control.

STEP 3

MOUNTING INSTRUCTIONS

1. DETERMINE THE BEST ESC MOUNTING LOCATION

The speed control should be positioned away from
the receiver and antenna as shown in set-up photo on
back page. Choose a mounting position that will keep
power wires away from the receiver and antenna.
Choose a position that will provide maximum airflow
through the heat sinks to allow for proper cooling.

2. INSTALL THE SPEED CONTROL

Use the included double-sided tape to mount ESC.

3. INSTALL THE ON/OFF SWITCH

Determine a convenient place to mount switch where
it will be easy to get to. Mount switch using a piece of
double-sided tape. If your car has a switch mount
molded into the chassis, remove the two phillips head
screws from the switch housing and reassemble
switch into chassis using the 3/8" long screws that are
included in the speed controls accessory kit. Note the
direction of ON/OFF cover and reverse it if necessary.

4. INSTALL THE RECEIVER

Mount the receiver as far from the speed control,
motor, power wires, battery, and servo as possible.
These components all emit radio noise when the
throttle is being applied. If your car has a graphite or
aluminum chassis, place the receiver on its edge with
the crystal and antenna as far above the chassis as
possible. The receiver can also be mounted on the
shock tower. Mount the antenna close to the receiver
and trail any excess wire off the top of the antenna.

5. INSTALL THE ANTENNA

Mount the antenna as close to the receiver as pos­sible. Trail any excess wire off the top of the antenna
mast. Do not cut or coil excess wire––range will be reduced.

FIGURE 3 Insert each pin into the correct plug slot. Each
pin should "click" into place.

(Airtronics plug shown)

WHT = White wire terminal (signal)
BLK = Black wire terminal (negative)
RED= Red wire terminal (positive)

CAUTION Improper installation of these wires may cause damage

to the receiver, servo, and speed control.

The locking tab must not extend
outside the plastic plug housing.

NOVAK ELECTRONICS, INC.

18910 Teller Avenue

Irvine, CA 92715

STEP 4

HOOK-UP INSTRUCTIONS

Refer to set-up photo below

1. INSTALL MOTOR CAPACITORS

Electric motors generate radio noise that can interfere
with your receiver and cause radio problems. Included
in the accessory kit with the speed control are three

0.1µF (50V) non-polarized, ceramic capacitors. These
capacitors muse be installed on every motor to help
reduce the noise generated by the motor and also to
prevent possible damage to the speed control.

Solder 0.1µF (50V) capacitors between:

• POSITIVE (+) motor tab & NEGATIVE (-) motor tab.

• POSITIVE (+) motor tab & GROUND tab*.

• NEGATIVE (-) motor tab & GROUND tab*.

*If your motor does not have a ground tab, solder the
capacitor leads to the can of the motor as shown below.

Negative (-) motor tab

0.1µF Capacitors

Schottky diode

Positive (+) motor tab

Extra 0.1µF capacitors
available in Novak kit #5620.

2. CONNECT SPEED CONTROL TO THE RECEIVER

After the proper input plug plastic has been installed
to match the receiver (Refer to Step 1), plug the speed
control into the THROTTLE CHANNEL of the receiver.

3.

CONNECT SPEED CONTROL TO THE BATTERY PACK

Plug the white JST connector from the speed control
into the JST/Tamiya style connector on a fully charged
6 or 7 cell battery pack (1.2 volts DC/cell). The black
wire is negative (-) and the red wire is positive (+).

4. CONNECT SPEED CONTROL TO THE MOTOR

Plug the bullet connector on the red wire (+) of the
speed control to motor positive. Plug the other bullet
connector, on the blue wire (-), to motor negative.

USE ONLY STOCK AND MILD MODIFIED MOTORS with
the Explorer speed control––Using hotter motors and
lower gear ratios will cause speed control to overheat.

A wiring kit with bullet connectors and a JST/Tamiya
connector is available in Novak kit #5810.

TIP: Twisting the BLUE & RED motor wires one or two times around
each other as they go to motor can help reduce any radio noise
that may be emitted from the power wires. Refer to Set-Up photo.

5. OPTIONAL USE OF SCHOTTKY DIODE

The Explorer does not require an external Schottky
diode. However, using one will increase the efficiency
and reduce the operating temperature of the ESC.

Solder the lead

CLOSEST

of the Schottky diode to the POSITIVE (+) motor tab.
Solder the lead OPPOSITE the silver stripe on the body

of the Schottky to the NEGATIVE (-) motor tab.

Schottky diodes are available in Novak kit #5640.

If installed backwards, a Schottky diode will be destroyed. The body
of a bad diode will normally crack open. Replace only with
diodes that have a minimum rating of 35 volts / 8 amps.

Ground / motor can

to the silver stripe on the body

Schottky

EXPLORER SET-UP

Trail excess wire

off antenna mast.

(Do not cut or coil)

Keep receiver
and antenna

away from

motor, servo,

battery, and
power wires.

(-)

(+)

red wire

(motor posative)

Tip: Twist motor wires

to reduce radio noise!

red wire

(battery positive)

black wire

(battery negative)

(-) (+)

blue wire

(motor negative)

Mount switch

where it will be

easy to get to.

STEP 5

TRANSMITTER ADJUSTMENT

Proper transmitter adjustment is important for optimum
performance from your speed control. The basic throttle
channel adjustments for the transmitter are as follows:

For proper ESC operation adjust transmitter as follows:

1. Set HIGH ATV or EPA to maximum setting.

[Controls amount of throw from neutral to full throttle]

2. Set LOW ATV , EPA , or ATL to maximum .

[Controls amount of throw from neutral to full brakes]

[Reduce this after ESC adjustment to reduce amount of brakes]

3. Set EXPONENTIAL to zero .

[Controls the linearity of the throttle channel]

4. Set THROTTLE CHANNEL TRIM to middle setting.

[Adjusts the neutral position of speed control]

[Increase or decrease after ESC adjustment to adjust coast
brakes––can be used to give braking in neutral trigger position]

5. Set THROTTLE CHANNEL REVERSING SWITCH to
normal position.

6. Set MECHANICAL THROW ADJUSTMENT to position

with 2/3 throttle and 1/3 brake throw.

[Adjusts pistol-grip transmitter’s throttle trigger throw]

STEP 6

SPEED CONTROL ADJUSTMENT

Before beginning this step, the speed control should be
connected to the receiver and to a charged 6 or 7 cell
battery pack, and the transmitter should be adjusted.

Adjustment of your Explorer speed control is required for
proper operation. When the status LED is red, the speed
control is in the neutral position (no throttle or brake).
When the status LED is green, the speed control is either at
the full throttle or full brake position.

When adjusting the speed control, DO NOT rotate the
pots beyond their end stops––this will damage the pots.

1. DISCONNECT THE MOTOR

The motor is not needed for adjustments.

2. CONNECT THE BATTERY

Plug the Explorer Sport into a fully charged 6 or 7 cell
battery pack.

3. TURN ON THE TRANSMITTER POWER

4. TURN ON THE SPEED CONTROL

Slide the ON/OFF switch to the ON position.

5. ADJUST THE NEUTRAL POT OF SPEED CONTROL

Rotate the NEUTRAL pot on the speed control until the
status LED turns solid red.

6. ADJUST THE HIGH SPEED POT OF SPEED CONTROL

Hold the transmitter throttle at full throttle and rotate
the HIGH SPEED pot on speed control until the status

LED turns solid green.

NOTE: If the HIGH SPEED pot is adjusted too high you will
reach full speed before the transmitter is at full throttle.

7. SET THE BRAKES TO MAXIMUM AT TRANSMITTER

Hold the transmitter throttle at full brakes and rotate
the LOW ATV , EPA, or ATL adjustment on the transmit-
ter until the status LED begins to turn green. After speed

control adjustment has been completed this setting can be
reduced if you feel there is too much braking.

NOTE: If the LOW ATV, EPA, or ATL on the transmitter is
adjusted too high you will reach full brakes before the
transmitter is at full brakes.

8. CHECK OPERATION OF THE SPEED CONTROL

Connect the motor and check for proper operation.
With no throttle or brake applied the status LED should
be solid red and the motor should not be running. At
full throttle the status LED should be solid green and
the motor running full speed. At full brakes the status
LED should be flickering green or solid green and the
motor should not be running.

NOTE: If the motor runs when the brakes are applied and
stops when the throttle is pulled, change the THROTTLE

CHANNEL REVERSING SWITCH position and repeat the Speed

Control Adjustment procedures.

9. SET THE COAST BRAKE AT TRANSMITTER (optional)

Adjust the THROTTLE CHANNEL TRIM on the transmit-
ter to get more or less coast brake. This is accomplished
by slightly shifting the neutral position. After adjustment

be sure that the status LED is still green at full throttle.

BRAKE LIGHTS

The Explorer speed control is equipped with a built in brake
light circuit that can power two LEDs. A complete brake light
accessory kit is available from Novak (kit #5655) and includes
two high power LEDs, two brake light mounting brackets that
allow mounting to most any vertical or horizontal surface of
the car (including inside the tail light area of the body), double-
sided tape, and wiring.

To connect brake lights to the Explorer Sport:

1. Strip about 1/8" of insulation off of both the red and the

black small (26 gauge) wires that exit the back of the
speed control along with the battery and motor wires.

2. Strip about 1/8" of insulation off both ends of the small (26
gauge) extension wires that are the correct length to reach
the position that the brake light is mounted.

3. Solder extension wires onto the brake light wires from the
speed control. If two LEDs are to be used, then solder two
extension wires to each brake light wire from the speed
control. Insulate solder joints with heat shrink tubing.

4. Solder the end of the extension wire from the black brake
light wire to the lead on the notched or flat side of the LED.
Solder the end of the extension wire from the
light wire to the other lead of the LED. Insulate
with heat shrink tubing.

red brake

solder joints

TROUBLE-SHOOTING GUIDE

This section describes possible speed control problems,
causes, and solutions.

Steering Channel Works But Motor Will Not Run

• Speed control has thermally shut down––Allow ESC to
cool down––Use milder motor or smaller pinion gear.

• Check motor connections. Check motor and brushes.

• Make sure ESC is plugged into the throttle channel of
receiver. Check throttle channel operation with a servo.
Check wiring color sequence of receiver signal harness.

• Possible internal damage––Refer to Service Procedures.

Receiver Glitches/Throttle Stutters During Acceleration

• Motor capacitors broken or missing––Refer to Step 4.

• Receiver or antenna too close to speed control, power
wires, battery, or motor––Refer to Step 3.

• Bad connections––Check wiring and connectors.

• Excessive current to motor––Use a milder motor or a
smaller pinion gear.

Motor and Steering Servo Do Not Work

• Check wires, receiver signal harness wiring and color
sequence, radio system, crystals, battery and motor
connectors, and battery pack.

• Possible internal damage––Refer to Service Procedures.

Model Runs Slowly / Slow Acceleration

•

Check motor and battery connectors––Replace if needed.

• Bad battery or motor––Check operation with another.

• Incorrect transmitter or speed control adjustment––
Refer to Steps 5 and 6.

• Optional external Schottky diode (if used) installed
backwards or damaged––Refer to Step 4.

Motor Runs Backwards

• Motor wired backwards––Check wiring and reverse.

• Battery pack wired backwards––Check polarity.

ESC Is Melted Or Burnt/ESC Runs With Switch Off

• Internal damage––Refer to Service Procedures.

*For more help call our Customer Service Department.

SERVICE PROCEDURES

Before sending in your Explorer for service, review the
Trouble-Shooting guide and the instructions. The ESC
may appear to have failed when other problems exist.

PLEASE NOTE: Speed controls that operate normally
when received will be charged a minimum service fee
and return shipping costs.

WHAT TO SEND: Fill out all of the information requested
on the enclosed ESC SERVICE CARD and return it with
your speed control.

WARRANTY WORK:

For warranty work, you MUST CLAIM

WARRANTY on the ESC SERVICE CARD and include a
valid cash register receipt with purchase date on it, or an
invoice from previous service work. If warranty provisions
have been voided there will be a service charge.

SERVICE COSTS: Customer is responsible for all service
costs (parts, labor, and shipping/handling charges).
Speed controls returned UPS/COD CASH ONLY. See ESC
SERVICE CARD for other payment and shipping options.

ADDITIONAL NOTES:

• Hobby dealers or distributors are not authorized to
replace speed controls thought to be defective.

• If a hobby dealer returns your speed control for service,
submit a completed ESC SERVICE CARD to the dealer
and make sure it is included with the speed control.

• To provide the most efficient service possible to our
customers, it is not our policy to contact customers by
phone or mail.

• Novak Electronics, Inc. does not make any electronic
components (transistors, resistors, etc.) available for sale.

PRODUCT WARRANTY

Novak Electronics, Inc. guarantees the Explorer Sport to be free
from defects in materials and workmanship for a period of 90
days from original date of purchase

sales receipt)

components worn by use, damage from using less than 6 or
more than 7 cells
ing heat sinks, cross-connection of battery/motor, damage from
rotating pots beyond endpoints, damage from incorrect instal­lation of FET servo or receiver battery pack, damage from exces­sive force while installing heat sinks or adjusting pots, not install­ing three 0.1µF (50V) capacitors on motor, splices to switch or
receiver signal harnesses, damage from disassembling case,
tampering with internal electronics, allowing water, moisture, or
any other foreign material to enter ESC or get onto PC board,
incorrect installation of alternate input plug plastic, allowing ex­posed wiring to short-circuit, or any damage caused by a crash.

In no case shall our liability exceed product's original cost. We
reserve the right to modify warranty provisions without notice.

Because Novak Electronics, Inc. has no control over connection
and use of the ESC, no liability may be assumed nor will be ac­cepted for damage resulting from the use of this product. Every
ESC is thoroughly tested and cycled before leaving our facility
and is, therefore, considered operational. By the act of connect­ing/operating ESC, the user accepts all resulting liability.

. Warranty does not cover incorrect installation,

(1.2 volts DC/cell)

(verified by dated, itemized

input voltage, short-circuit-

CUSTOMER SERVICE

CUSTOMER SERVICE HOURS (PST)

Monday-Friday: 8:00am-4:00pm
[phone] • FAX [phone]

©1995 Novak Electronics, Inc. • All Rights Reserved
No part of these operating instructions may be reproduced without

the written permission of Novak Electronics, Inc.
All Novak speed controls are designed and manufactured in the U.S.A.
Explorer Sport™, Polar Drive Technology™, Solid State RVP™, and

Input Plug System™ are all trademarks of Novak Electronics, Inc.
Printed in the U.S.A. 12/95 • #IM-1900-1