NOVAK MONGOOSE CRAWLER - BASIC SETUP GUIDE 1-2009 Setup Manual

using a receiver battery pack
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. Leave the ESC's ON/OFF switch in the OFF position, and use receiver
battery pack's ON/OFF switch to turn the system power on and
off––Do not use the ESC's switch.
sensor harness wiring
Should any of the 26G Teflon wires pull out of the connector on the
end of the motor's sensor harness, re-insert them in the appropriate
slot in the connector as shown below. There is a small plastic tab that
grabs a small raised barb on the back of the metal socket crimped onto
the Teflon wire's end. The plastic tab should be checked to make sure
it has not deformed excessively before inserting the metal socket into
the plastic connector housing with the barb toward the plastic tabs.
FIGURE 6 FIGURE 7
If the motor's
black red raised
sensor harness
metal
orange blue
barb
gets damaged,
please contact white green
our Customer
Service Dept.
metal socket
plastic metal on end of Teflon
tabs barbs sensor harness wires
service procedures
Before sending your speed control or brushless motor system in for service,
review the product's instructions and Trouble-Shooting guide. The 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:
WEBSITE: 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:
• Dealers/distributors are not 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 Electronics, Inc. does not make any internal electronic components (transistors,
resistors, etc.) available for sale.
• Customers outside of the U.S./Canada, please contact the Novak Distributor in your
country (refer to www.teamnovak.com for complete international distributor list).
Novak Electronics, Inc.
17032 Armstrong Avenue
Irvine, CA 92614
(949) 833-8873 • FAX (949) 833-1631
Customer Service e-mail: cs@teamnovak.com
Monday-Friday: 8:00am-5:00pm (PST)
w w w . t e a m n o v a k . c o m
trouble-shooting guide
Steering Channel Works But Motor Will Not Run
•Red & Green status LEDs alternating–– Li-Po Cut-Off Circuitry activated.
Disconnect Li-Po battery pack and re-charge.
•Red & Green status LEDs on solid––
Check input signal harness
connections at ESC and receiver. Check input signal harness wiring
sequence––Refer to Step 1.
•Red status LED on solid & Green LED blinking––
Check motor sensor
harness connection. Possible internal motor damage.
•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––Refer
to Step 4.
• Possible receiver damage––Check operation with a different receiver.
• Possible internal damage––Refer to Service Procedures.
Throttle Stutters or Receiver Glitches During Acceleration
• Dead Band too tight––Increase ESC's Dead Band adjustment (see
Programming sheet).
• Receiver or antenna too close to ESC, power wires, battery, or motor.
• Bad connections––Check wiring, connectors, & sensor harness.
• Low voltage to receiver––Try Glitch Buster capacitor on receiver (Novak
#5626).
• External Power Capacitor damaged/not installed––Replace Power
Capacitor (Novak #5683).
• Battery pack damaged or weak––Try a different battery pack.
• Motor's magnet has weakened or overheated––Replace rotor.
Motor and Steering Servo Do Not Work
• Check wires, receiver signal harness wiring & color sequence, radio system,
crystals, battery/motor connectors, & battery pack.
• Power wires too close to signal wires––Do not bundle power & signal
wires together.
• Possible receiver damage––Check operation with a different receiver.
• Possible internal damage––Refer to Service Procedures.
Brushless Motor Runs Backwards
• Reverse motor rotation direction––Refer to 'Custom Programming' sheet.
Speed Control Runs Excessively Hot
• Gear ratio too low––Increase gear ratio (see 'PROPER GEAR SELECTION'
section).
Model Runs Slowly/Slow Acceleration
• Gear ratio too high––Reduce gear ratio (see 'PROPER GEAR SELECTION'
section).
• Check battery & connectors––Try another battery; replace connectors/
battery if needed.
• Incorrect transmitter/ESC adjustment––Refer to Step 4.
• External Power Capacitor damaged/not installed––Replace Power
Capacitor (Novak #5683).
ESC Is Melted Or Burnt/ESC Runs With Switch Off
• Internal damage––Refer to Service Procedures.
*For more assistance check our Web site or call our Customer Service Department.
P4
mongoose CRAWLER BASIC SET-UP GUIDE
• See 'Programming/Gearing' sheet for Proper Gearing, Profile Selection, Custom Programming & Li-Po Cut-Off •
#55-3055-1
1-2009
The Ultimate Micro-Rock Crawler for Brushless & Brush Motors and Full Programmability!
The Mongoose Crawler electronic speed control gives you the best of everything--Sensor-based brushless motor control, world
class brush motor performance with Auto-Detect Brush-Mode, complete on-board programming of Minimum Brake, Drag/Hill
Brake, Dead Band, Li-Po Cut-Off, Motor Rotation and Drive Frequency (in Brush Mode) ... all packed into a micro-sized crawler!
The Mongoose Crawler is factory-loaded with 4 throttle programs to choose from (including a Servo/Robotic mode), Novak's Crawler-exclusive brushless holding
power & linear ramp-up braking, Thermal Overload Protection, high-power B.E.C. for extra-strong/fast servo response, Polar Drive & Digital Anti-Glitch circuit-
ries for cool and smooth operation, auxiliary fan power output, and Radio Priority circuitry for the ultimate in control, right down to the end of the charge. Add
to this the user-replaceable battery wires, power capacitor and input harness, and the Mongoose Crawler has it all!
To benefit from all of the technical features of the Mongoose Crawler, PLEASE READ ALL INSTRUCTIONS BEFORE OPERATION
PRECAuTIONS
WATER & ELECTRONICS DON'T MIX!
Never allow water, moisture or other foreign materials to get inside ESC, motor
or on the PC Boards. Water damage will void the warranty!
NOVAK BRUSHLESS MOTORS ONLY
The Mongoose Crawler is designed for use with sensor-based Novak Three-80 Crawler
Motors (18.5T minimum). Any motor used must have Thermal Overload Protection. Check
the Novak Web site for motor compatibility. Using a Novak Three-80 motor (Novak #3450-
3452) is acceptable, but the ESC will default to the Mongoose non-crawling default profile.
DISCONNECT BATTERIES WHEN NOT IN USE
Always disconnect the battery pack from the speed control when not in use to
avoid short circuits and possible fire hazard.
2-3 CELL LI-PO ONLY OR 4 TO 9 CELLS
If using Li-Po batteries, ONLY use a 2-cell (2S) or 3-cell (3S) pack for the vehicle's
main battery & be sure the Li-Po Cut-Off programming option is turned ON.
If using Ni-Cd or Ni-MH batteries, NEVER use fewer than 4 or more than 9 cells
(1.2VDC/cell) in the vehicle's main battery pack.
NO SCHOTTKY DIODE!
Schottky diodes must NOT be used in Brushless-Mode or Brushed-Mode with the
Mongoose Crawler (Schottky diodes are never used with reversible ESCs, including brushless).
Schottky diode usage will damage ESC & void warranty.
NO REVERSE VOLTAGE!
Reverse battery polarity can damage ESC & void warranty. Disconnect battery
immediately if a reverse connection occurs.
POWER CAPACITOR REQUIRED
An external power capacitor is installed on ESC & MUST be used. Failure to use
Capacitor may result in higher temperatures & possible thermal shut-down or damage.
TRANSMITTER ON FIRST
Always turn on the power of the transmitter first so that you will have control of
the vehicle when you turn it on.
GOOD QUALITY TRANSMITTER SUGGESTED
With the higher performance of brushless systems, undesirable radio system noise
may occur when used with lower quality transmitters (like some RTR radios).
The current transmitter that is included in the Losi ® Mini Rock Crawler™—LSR-3000
DSM Transmitter: MLST2—is acceptable to be used with the Mongoose Crawler.
DO NOT BUNDLE POWER & SIGNAL WIRES TOGETHER
RF noise in the power wires can adversely effect radio system performance.
INSULATE WIRES
Always insulate exposed wiring with heat shrink tubing (Novak #5850/#5851) or
electrical tape to prevent short circuits, which can damage ESC.
NO CA GLUE
Exposure to CA glue or its fumes can cause damage to internal components of
the speed control and result in premature failure.
SPECIFICATIONS
Input Voltage ...2-3 Li-Po cells, 4-9 Ni-MH/Ni-Cd cells
ESC Footprint .........................................1.15"x0.95"
ESC Weight ..................................0.77 ounce
(w/o wires)
B.E.C. Voltage/Current ............................... 6.0 volts DC/2.0 amps
Power Wire ......................... 16G Super-Flex Silicone
(Battery/Motor)
On-Resistance (Brushless/Brush) ........ 0.0038Ω/phase
@25°C trans.temp.
Rated Current (Brushless) ....................40A
[per phase] @25°C trans.temp.
Rated Current (Brush-Mode) ........... 40A [Fwd & Brakes]
@25°C trans.temp.
Motor Limit (Brushless) ......................... 18.5-turn [380-size or smaller]
Motor Limit (Brush-Mode) ....................... 22-turn
[380-size or smaller]
Throttle Programs (Brushless) ........................ 3
[2 crawling & 1 robotic]
Throttle Program (Brush-Mode) ........................1
[Fwd/Drag Brake/Rev]
Programmable ......................................................................... Yes
optional accessories
Novak offers six pinion gear sets that are compatible with micro vehicles:
Mod 0.6 Pinion Gear Sets 11T/12T/13T (#5200), 14T/15T/16T (#5201) & 17T/18T/19T (#5202)
Mod 0.5 Pinion Gear Sets 11T/12T/13T (#5210), 14T/15T/16T (#5211) & 17T/18T/19T (#5212)
Novak's 1/8" Mod 0.5 Pinion Gear: 15T (#5211) is recommended to use with the Losi
Rock Crawler™.
5304 Input Plug Harness--Mini--Replacement Mongoose 2mm-to-JST input signal harness
5509 16GA Brushless Wire Set--2 pieces each of 9" silicone blue, yellow, orange, black & red
5600 ESC Switch Harness--Replacement ON/OFF switch harness for speed controls
5647 Black Cooling Fan--25x25x10mm--All purpose cooling fan with 2-pin JST connector
5683 Power Trans-Cap Module--Mongoose--Replacement power capacitor module
5721 2mm Power Connectors--5 pair--Gold plated low-loss 16-20G power connectors
5825 Micro Battery Cross Bars--7pcs--Oxygen-free copper micro battery bars
5826 Micro Battery Cross Bars--28pcs--O xygen-free copper micro battery bars
5831 Lead-Free 3% Silver Racing Solder--6g--Low-resistance, high-conductivity solder
5832 Lead-Free 3% Silver Racing Solder--15g--Low-resistance, high-conductivity solder
5833 Lead-Free 3% Silver Racing Solder--100g--Low-resistance, high-conductivity solder
5840 Double-Sided Mounting Tape--10pcs--1"x1" high-performance clear mounting tape
5850 Heat Shrink Tubing Assortment--6pcs--dependable, clean heat shrink tubing
5851 Heat Shrink Tubing Assortment--24pcs--dependable, clean heat shrink tubing
5915 Three-80 Sintered Rotor--Replacement sintered neodymium rotor for Three-80 motors
5916 Three-80 Front End Bell & Bearings--Replacement front end bell & both bearings
product warranty
The Mongoose Crawler Brushless ESC is guaranteed to be free from defects in materials or workmanship for a
period of 120 days from the original date of purchase (verified by dated, itemized sales receipt). Warranty does
not cover incorrect installation, components worn by use, damage to case or exposed circuit boards, dam-
age from using fewer than 4 or more than 9 cells (1.2 volts DC/cell) or more than 3 Li-Po cells input voltage,
cross-connection of battery/motor power wires, overheating solder tabs, reverse voltage application, damage
resulting from thermal overload or short-circuiting motor (or connecting a brushless motor sensor harness
while operating in Brush-Mode), damage from incorrect installation of FET servo or receiver battery pack, not
using or incorrect installation of a Power Capacitor on the ESC or from using a damaged Power Capacitor,
using a Schottky diode, using non-Novak Power Capacitor or motor, 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 the connection & use of the speed control 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
speed control & motor is thoroughly tested & cycled before leaving our facility and is, therefore, considered
operational. By the act of connecting/operating speed control, 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. Designed by Novak Electronics, Inc. in Irvine, CA and assembled with globally sourced components.
©2009 Novak Electronics, Inc. • All Rights Reserved • No part of these instructions may be reproduced
without the written permission of Novak Electronics, Inc. • Mongoose Crawler ESC, Smart Braking II, Polar
Drive Technology, Radio Priority Circuitry, & One-Touch Set-Up are all trademarks of Novak Electronics, Inc.
P1
[1.2 VDC/cell]
[29.0x24.3mm]
[22 grams]
Mini
®