NOVAK GTB BRUSHLESS RACING ESC - 4-2007, Setup Manual

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BRUSHLESS S RACING ESC
#55-1710-2
4-2007
SPECIFICATIONS
PRECAuTIONS
optional accessories
P1 P4
✫✪✼✲✬✄✼✮✽✑✾✹✄✰✾✲✭✮✄✑✑✄✰✽✫
using a receiver battery pack using a receiver battery pack using a receiver battery pack using a receiver battery pack using a receiver battery pack
step step step step step
5 5
5 5
5
–
one-touch programming
•NOT ALL TRANSMITTERS HA
VE THESE ADJUSTMENTS•
step step
step step step
4 4 4 4 4
–
transmitter adjustments
step step
step step step
3 3 3 3 3
–
MOUNTiNG ESC
product warranty product warranty
product warranty product warranty
product warranty
The GTB 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, damage from using
fewer than 4 or more than 6 cells (1.2 volts DC/cell) input voltage, cross-connection of battery/motor power
wires, damage from cross phase connection, overheating solder tabs, reverse voltage application, damage result-
ing 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 in Brushless-Mode, 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 act of God.
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. 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.
©2007 Novak Electronics, Inc. • All Rights Reserved • No part of these instructions may be reproduced
without the written permission of Novak Electronics, Inc. • GTB ESC, Smart Braking II, Polar Drive
Technology, Radio Priority Circuitry, & One-Touch Set-Up are all trademarks of Novak Electronics, Inc. •
All Novak speed controls & motors are designed & assembled in the U.S.A.
Replacement RACING POWER TRANS-CAP MODULE
The factory-installed GTB Racing Power Trans-Cap Module MUST BE USED for proper
operation. Replacement GTB Power Trans-Cap Module is available in Novak kit #5679.
Note: We recommend using Novak Power Trans-Caps only. We’ve done extensive testing & research to
find components with the very best quality factors––other capacitors will not provide equal protection.
SUPER-FLEX SILICONE 14G WIRE
Novak Super-Flex wire for power wiring. 14 gauge silicone wire in kit #5500
(36”red & 36”black) and kit #5508 (2 each of 9”red/black/blue/yellow/orange).
INPUT SIGNAL HARNESSES
The 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 .
VELOCiTi MOTOR BEARING & END BELL SET
After extensive use, the ball bearings in the motor may need replacement. Velociti
front end bell with bearing factory-installed & rear bearing are available in Novak kit
#5920 or 5919.
VELOCiTi MOTOR REPLACEMENT ROTOR
After extensive use, the motor’s rotor may need replacement due to loss of magnetic
strength
(normal after extended use) . Replacement Velociti rotor available in Novak kit #5908.
Replacement GTB 30x30x8mm HIGH-VOLUME COOLING FANS
The GTB High-Volume Cooling Fan should be used for increased ESC efficiency.
Replacement GTB Cooling Fan available in Novak kit #5648, 2-pack of fans in kit #5652.
Replacement REMOTE POWER PROGRAMMING SWITCH
The GTB’s combination Power ON/OFF Switch & One-Touch Programming Button is
available as a replacement harness in Novak kit #5602.
Brushless & brush motor control and complete programmability in one electronic racing speed control!
The GTB racing ESC gives you the best of both worlds--brush & sensor-based brushless motor control. Combine this with on-board programming
of Minimum Drive, Minimum Brake, Drag Brake, & Deadband (plus Drive Frequency in Brush-Mode), and you’ve got extreme versatility.
The GTB comes with 6 throttle profiles, built-in Li-Po Cut-Off Circuitry , Thermal Overload Protection , high-power B.E.C. for strong/fast servo response, 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 water-resistant case and user-replaceable input harness, battery & motor wires, Power Trans-Cap Module, & combination ON/OFF switch/One-Touch
button, and the GTB is loaded !
To benefit from all of the technical features of the GTB, PLEASE READ ALL INSTRUCTIONS
Input Voltage ..................... 4-6 cells (1.2 volts DC/cell or 2 Li-Poly cells)
ESC Footprint ....................................... 1.16”x1.49” [29.5x37.8mm]
ESC Weight
(w/o wires) .......................................
1.36 ounce
[38.5 grams]
B.E.C. Voltage/Current ............................... 6.0 volts DC/3.0 amps
Power Wire
(Battery/Motor) ...............................
14G Super-Flex Silicone
On-Resistance (Brushless) ............................... 0.00040
Ω
@25
°
C trans.temp.
On-Resistance (Brush-Mode) .......................... 0.00013
Ω
@25
°
C trans.temp.
Rated Current ( Brushless --per phase ) ............ 540A [Fwd & Rev.] @25
°
C trans.temp.
Rated Current
(Brush-Mode) ..............
1620A
[Fwd & Brakes] @25
°
C trans.temp.
Motor Limit
(Brushless) .....................
None
[compatible with any Novak motor]
Motor Limit (Brush-Mode) ..................................................................... None
Throttle Programs (Brushless) ..................... 5 [3 Fwd/Brake only & 2 w/Rev.]
Throttle Program (Brush-Mode) ........................................ 1 [Fwd/Brake only]
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 IN BRUSHLESS-MODE !
Schottky diodes must NOT be used when using ESC in Brushless-Mode
(Schottky diodes are never used with reversible ESCs, including brushless) .
Schottky diode usage in Brushless-Mode will damage ESC & void warranty.
TAKE CARE WHEN SWITCHING ESC MODES
Severe ESC damage can occur if proper procedures are not followed
when switching ESC between Brush-Mode & Brushless-Mode.
Refer to PROGRAMMING/GEARING sheet page 5 for detailed instructions.
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.
4 TO 6 CELLS OR 2 LI-PO CELLS ONLY
Never use fewer than 4 or more than 6 cells (4.8-7.2VDC, 1.2VDC/cell)
in the vehicle’s main battery pack, or more than 2 Li-Poly cells.
NOVAK BRUSHLESS MOTORS ONLY
When in the Brushless-Mode, the GTB speed control is specifically
designed for use with sensor-based Novak Brushless Motors Only!
You may replace motor with any Novak sensor-based motor or Novak approved
motor--see website for up to date motor listings, updates, & compatibilities.
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 Module is installed and MUST be used
with your ESC. Failure to use Power Capacitor will result in higher ESC
operating temperatures & possible thermal shut-down.
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 CA GLUE
Exposure to CA glue or its fumes can cause damage to internal
components of the speed control and result in premature failure.
trouble-shooting guide trouble-shooting guide trouble-shooting guide trouble-shooting guide trouble-shooting guide
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.
Motor sensor harness connected while in Brush-Mode––disconnect sensor harness.
• 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 Steps 4 & 5.
• Red status LEDs toggling. Li-po Safety Cut-Off has been activated.
• 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 Capacitor damaged/not installed––Replace Power Capacitor.
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 (see ‘GEAR SELECTION’) .
Model Runs Slowly/Slow Acceleration
• Gear ratio too high––Reduce gear ratio (see ‘GEAR SELECTION’) .
• Check battery connectors––Replace if needed.
• Incorrect transmitter/ESC adjustment––Refer to Steps 4 & 5.
• External Power Capacitor damaged/not installed––Replace Power Capacitor.
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 website.
service procedures service procedures service procedures service procedures service procedures
Before sending your speed control or brushless motor system in for
service, review Trouble-Shooting guide and 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:
WEBSITE: Print a copy of the PRODUCT SERVICE FORM from the CUSTOMER SERVICE
section of the website. 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 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 Electronics, Inc. does not make any internal electronic components (transistors,
resistors, etc.) available for sale.
Novak Electronics, Inc.
(949) 833-8873 • FAX (949) 833-1631
Customer Service e-mail: cs@teamnovak.com
Monday-Thursday: 8:00am-5:00pm (PST)
Friday: 8:00am-4:00pm (closed every other Friday)
w w w . t e a m n o v a k . c o m
If you are planning to use an external receiver battery pack to power the elec-
tronics 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 & use receiver pack’s
ON/OFF switch to turn system power on and off ––Do not use the ESC’s switch.
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 GTB’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.
REMEMBER: Whenever One-Touch set-up is performed, ESC automatically reverts to factory
default settings & the Throttle Profile reverts to #1 when in Brushless-Mode.
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]
Mount ESC with power wires away from other electronics & moving parts.
Select a location that allows good airflow through and around the heat sink
and cooling fan--
Good air flow allows ESC to run cooler and more efficient!
1. MOUNT ESC IN VEHICLE using the included double-sided tape. Be sure
the receiver & antenna are mounted as far from ESC, power wires, battery,
& servo as possible--these components all emit RF noise when the 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 the antenna as close to the receiver as possible--trail any excess wire off the top
of the antenna mast (cutting or coiling the excess antenna wire will reduce radio range).
2. SECURE POWER TRANS-CAP MODULE IN VEHICLE
Use the included double-sided tape to mount the Power Trans-Cap
Module to the chassis with the included double-sided tape. Module can
also be tie-wrapped to the power wires or other part of chassis or shock
tower with the included tie-wraps.
3. INSTALL REMOTE POWER PROGRAMMING SWITCH with the included
double-sided tape where it will be easy to access for turning the electronics
on & off and also for programming the GTB’s throttle profiles or switching
between Brushless and Brush-Modes.