NOVAK ROOSTER CRAWLER ESC - BASIC SETUP GUIDE V2 4-2010 Setup Manual

L I - P O C U T- O F F C I R C U I T R Y
The Rooster Crawler ESC has a built-in Novak Smart-Stop Li-Po Cut-Off
Circuitry for safe, worry-free operation when using Lithium Polymer batteries.
When the speed control is in Throttle Profile 2, the Smart-Stop Li-Po Cut-Off
circuitry is active.
The Smart-Stop Cut-Off circuitry constantly monitors the Li-Po battery's
pack voltage. When the pack's voltage begins to get close to the critical
safety voltage, the Cut-Off circuitry will start interrupting, or 'blipping' the
throttle output. This 'blipping' acts as an early warning to you that the battery
voltage is getting low, and that the throttle output to the motor will soon
be completely shut off. At this point, you should stop driving to save your
battery from damage.
When the battery pack's critical safety voltage is finally reached, the Smart-
Stop Cut-Off circuitry will completely shut down the throttle output signal to
the motor to keep the battery voltage from dropping further (Red & Green
LEDs will alternately flash--you will still have steering control). Re-charge battery
pack after Smart-Stop circuitry shuts off throttle.
After a short resting period, the battery's voltage will rise back above the
critical safety voltage, and the ESC will operate normally again for a short
period of time. This is not good for the battery pack, as reaching the
critical safety voltage too many times can also cause damage to the
cells. DO NOT CONTINUE TO RUN VEHICLE AFTER THE SMART-STOP
HAS SHUT DOWN THE THROTTLE OUTPUT FOR THE FIRST TIME.
If Throttle Profile 2 is used with Ni-Cd or Ni-MH type batteries, the cut-off
circuitry will shut off the speed control's throttle output very early into the
battery pack's runtime, due to the different characteristics of these batteries–
–Change ESC's Throttle Profile to Profile 1 for use with these batteries.
A U X I L I A R Y F A N C O N N E C T I O N
The Rooster Crawler ESC also features a set of power output pins for running
auxiliary cooling fans. This allows you to add cooling fans to either the motor,
the speed control, or both, and the best part is that they will automatically
switch off when you turn off the speed control's power switch.
These pins output 6.0 volts DC (the same as the BEC), so you will get
maximum output from your cooling fans.
positive
fan pin
pin-out label
negative
fan pin
The Rooster's pin-out label located on the front lower section of the ESC's
case (under the pins, push button, & LEDs) shows the location and the polar-
ity of the fan power output pins. They are the 2 pins on the front edge of
the circuit board--Positive (+) is on the left, and Negative (–) is on the right.
The set of 3 pins behind them are for the user-replaceable input signal
harness, and the polarity of those is the same--Positive in the middle,
Negative on the right, and the extra pin on the left is signal.
The Novak 30x30x6mm clear cooling fan that comes on the GTB speed
control (Novak kit #5648) not only fits the size of the Rooster Crawler's
heat sink perfectly, it also comes with the connector already on it for directly
plugging in. Fans that do not have the proper connector on them, will need
a connector (one end of an old receiver input harness would work well), or will
need to be soldered to the pins--Take extra care if attempting to solder to
the fan power output pins--Do not overheat the pins or the circuit board,
and do not allow any solder or wire strands to cause a short circuit with
other pins or the heat sink.
NOVAK ELECTRONICS, INC.
w w w. t e a m n o v a k . c o m
(949) 833-8873 • FAX (949) 833-1631
Refer to Web site for service hours
and contact information
T R O U B L E - S H O O T I N G G U I D E
Steering Channel Works But Motor Will Not Run
• Red LED flashing: Speed control has thermally shut down––Allow ESC to
cool down––Use milder motor or smaller pinion gear––Check for adequate
cooling to ESC's heat sink.
• Red & Green LEDs alternately flashing: Smart-Stop Li-Po circuitry has
shut off throttle output––Use a charged Li-Po battery. Using Ni-Cd or Ni-MH
batteries with ESC in Profile 2––change battery type or ESC Profile.
• Check motor connections. Check motor and brushes.
• Make sure ESC is plugged into the throttle channel of receiver. Check
wiring color sequence of receiver signal harness (Refer to Step 1).
• 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.
• Motor capacitors broken or missing––Refer to Step 3.
• Excessive current to motor––Use a milder motor or a smaller pinion gear.
• External Power Capacitor damaged/not installed––Replace Capacitor.
Untidy Wires
• 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.
Speed Control Runs Excessively Hot
• Gear ratio too low––Increase gear ratio (smaller sized-pinion gear).
• If motor is damaged, try a different motor.
Model Runs Slowly/Slow Acceleration
• Check battery connectors––Replace if needed.
• Incorrect ESC/transmitter adjustment––Refer to Step 4 & Transmitter
Adjustments sections.
• External Power Capacitor damaged/not installed––Replace Power Capacitor.
Motor Runs Backwards
• Motor wired backwards––Check wiring and reverse.
• Backwards motor timing––Reverse motor end bell.
ESC Is Melted Or Burnt/ESC Runs With Switch Off
• Internal damage––Refer to Service Procedures.
*For more assistance call our Customer Service Department or check our Web site.
S E R V I C E P R O C E D U R E S
Before sending in your ESC for service, please review the Trouble-Shooting
guide and instructions. Speed control may appear to have failed when
other problems exist.
After reviewing instructions, if you feel that your ESC 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 Novak 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 service, you MUST CLAIM
WARRANTY on the PRODUCT SERVICE FORM and 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 product 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.
P4
ROOSTER CRAWLER ESC – INSTRUCTIONS
#55-1841-1 Ver. 2
4-2010
Attention crawler enthusiasts — The Rooster is ready to crawl!
The Rooster Crawler Brushed speed control has crawler-specific throttle profiles, and is specially designed with
built-in Smart-Stop Li-Po Cut-Off circuitry and a 6 volt / 5 amp BEC. The rugged ESC brings you 27-turn and
higher motor handling, high-drag brake and is also the ideal partner for Novak's Crawler Brushed Motors.
The ESC also features Thermal Overload Protection, no Reverse Delay, Polar Drive & Digital Anti-Glitch circuitries for
cool & smooth operation and Radio Priority circuitry for the ultimate in control, right down to the end of the charge.
Add to this the user-replaceable power wires, power capacitor, & input harness, along with power output for auxiliary
cooling fans that turn on & off with the ESC's power switch, and the Rooster Crawler-Edition has it all!
To benefit from all of the technical features of the Rooster Crawler, PLEASE READ ALL INSTRUCTIONS
P R E C A U T I O N S
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.
27T SINGLE & 35T DUAL MOTOR LIMIT!
Do not use a single motor that is lower than 27-turns. For dual motors
for crawling, the motor range is 35 turns or above. A lower turn motor
may damage ESC.
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!
NO SCHOTTKY DIODE!
Schottky diodes must NOT be used with the Rooster Crawler ESC.
Schottky diode usage will damage ESC & void warranty!
4 TO 7 CELLS OR 2-CELL LI-PO ONLY
If using Ni-Cd or Ni-MH batteries, NEVER use fewer than 4 or more than
7 cells (4.8-8.4VDC, 1.2VDC/cell) in the vehicle's main battery pack.
If using Li-Po batteries, ONLY use a 2-cell pack for the vehicle's main
battery & be sure to use Profile 2 with the built-in Li-Po cut-off.
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 and MUST be used with your
ESC. Failure to use Power Capacitor will result in higher ESC operating
temperatures & ESC 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.
INSULATE WIRES
Always insulate exposed wiring with heat shrink tubing or electrical tape
to prevent short circuits, which can damage ESC.
NO SOLVENTS
Exposing the ESC's case to any type of solvents will damage the plastic.
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.
S P E C I F I C AT I O N S
Input Voltage .....................4-7 cells
(@1.2 volts DC/cell)
Li-Po Cut-Off Voltage .................................................6.25 volts DC
ESC Footprint ............................................. 1.18" x 1.54"
ESC Weight .................................. 1.57 ounce
(w/o wires)
B.E.C. Rating ............................................. 6.0 volts DC / 5.0 amps
Power Wire (Battery/Motor) ...........................14G Super-Flex Silicone
Rated Current ....................... 400A Fwd / 200A Rev
On-Resistance ............... 0.0014Ω Fwd / 0.0028Ω Rev
Motor Limit ......................... 27 turn
(single) [@ 6 cells
Motor Limit (dual) ........................... 35 turn [@ 6 cells
Throttle Profiles .................................................... 2
Switched Fan Output ...................................................6.0 volts DC
Terra Claw Crawling (#3556)
Forty-Five Crawler (#3545)
Fifty-Five Crawler (#3555)
O P T I O N A L A C C E S S O R I E S
REPLACEMENT POWER CAPACITOR
[Novak kit #5682]
The Rooster Crawler-Edition ESC comes with a factory-installed Power Capacitor,
and it MUST BE USED to maintain cool and smooth operation. A direct replacement
Power Capacitor is available in Novak kit #5682.
Note: We highly recommend using Novak Power Capacitors, as we have done extensive testing & research
to find Power Capacitors with the very best quality factors––other capacitors with similar ratings will not
provide equal protection.
SUPER-FLEX SILICONE 14G WIRE
[Novak kit #5514]
Novak Super-Flex wire for power wiring. 14 gauge silicone wire in kit #5514
(36"black, 36"red, & 36"blue).
INPUT SIGNAL HARNESS [Novak kits #5315 & 5320]
User-replaceable input signal harness is available in both short and long lengths.
4.5" harness in Novak kit#5315, and 9.0" harness in Novak kit #5320.
MOTOR CAPACITORS
[Novak kit #5620]
Additional motor capacitors are available in Novak kit #5620.
AUXILIARY COOLING FANS [Novak kits #5647 & #5648]
The Rooster Crawler comes with power output pins ready to add a cooling fan
that will switch on & off with the ESC's power switch.
Novak 25x25x10mm fan with long leads for cooling motor is available in Novak kit
#5647. Novak 30x30x6mm clear fan that fits perfect over the ESC's heat sink and
has a connector already on its leads is available in Novak kit #5648.
P R O D U C T W A R R A N T Y
The Rooster Crawler 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, damage from using fewer than 4 or more than 7
Ni-Cd or Ni-MH cells (1.2 volts DC/cell) or fewer or more than 2 Li-Po cells input voltage, cross-connection of battery/
motor power wires, overheating solder tabs, reverse voltage application, damage resulting from thermal overload, damage
from incorrect installation of FET servo or receiver battery pack, not using or incorrect installation of a Power Capacitor on
ESC or from using a damaged Power Capacitor, using a Schottky diode, using non-Novak Power Capacitor, splices to input
or ON/OFF switch 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 motor/battery connectors, input plug plastic, or auxiliary cooling fan,
allowing exposed wiring, pins, or solder tabs to short-circuit, or any damage caused by a crash, flooding or natural disaster.
Because Novak Electronics, Inc. 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,
including battery packs. 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.
©2010 Novak Electronics, Inc. • All Rights Reserved • No part of these instructions may be reproduced without the writ-
ten permission of Novak Electronics, Inc. • Rooster Crawler ESC, Polar Drive Technology, Radio Priority Circuitry,
& One-Touch Set-Up are all trademarks of Novak Electronics, Inc. • All Novak speed controls are designed &
assembled in Irvine, CA, and are Lead-Free & RoHS compliant.
P1
/ 2 Li-Po cells
[30x39mm]
[44.5 grams]
@25°C trans.temp.
@25°C trans.temp.
Ni-MH(1.2VDC/cell) ]
]
Ni-MH(1.2VDC/cell)
[1 with Li-Po Cut-Off]