Manual of Sensorless Brushless Speed Controller

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Manual of Sensorless Brushless Speed Controller | Manualzz

Manual of Sensorless Brushless Speed Controller

HW-SM002DUL-20130610

Thanks for purchasing our Electronic Speed Controller (ESC). High power system for RC model can be very dangerous, so we strongly suggest you read this manual carefully. In that we have no control over the correct use, installation, application, or maintenance of our products, no liability shall be assumed nor accepted for any damages, losses or costs resulting from the use of

Begin To Use The New ESC

Note: In the following instructions, we use the words of “Top position” and “Bottom position” to represent the position of the throttle stick.

Top Position: The throttle value is 100% at this position. the product. Any claims arising from the operating, failure or malfunctioning etc. will be denied. We assume no liability for personal injury, property damage or consequential damages resulting from our product or our workmanship. As far as is legally permitted, the

Bottom Position: The throttle value is 0% at this position. obligation to compensation is limited to the invoice amount of the affected product.

Before using your new ESC, please check all the connections to make sure that they are reliable, and then start up the ESC in the following sequence:

Features

1. Use extreme low resistance PCB to make the whole ESC with super current endurance capability.

2. Military quality capacitors with extreme low resistance increase the ability for preventing unwanted RF noise or interference.

3. Anti-spark circuit eliminates sparks when the battery pack is connecting with the ESC.

4. Protection features: Low-voltage cutoff protection / over-heat protection / throttle signal lost protection.

5. 3 start modes: Normal / Soft / Super-Soft, compatible with fixed-wing aircraft and helicopter.

6. Throttle range can be configured, fully compatible with all transmitters.

7. Smooth and accurate speed control, excellent throttle linearity.

8. Maximum speed: 210000 RPM (2 poles motor), 70000 RPM (6 poles motor), 35000 RPM (12 poles motor).

9. Pocket- sized program card can be purchased separately for extremely easy programming of the ESC at flying field.

1. Move the throttle stick to bottom, and then switch on the transmitter.

2. Connect the receiver battery pack (4-6V) to the receiver, and then connect the main power battery pack to ESC, the ESC begins the selftest process, and the motor will emit several “beep” tones to represent the cells quantity of the lithium battery pack. After 2 seconds a long “beep------”tone emits, which means the self-test is OK, and now the RC model is ready to take off.

 If nothing is happened, please check your battery packs and all the connections;

 If a special tone “ ” emits after 2 beep tones (beep-beep-), means the ESC has entered the program mode, i.e. the throttle channel of your transmitter is reversed, please set the direction of throttle channel correctly.

 If a very rapid “beep-beep-, beep-beep-” tone emits (The time interval of each “beep-beep-” tone is 1 second), means the input voltage is too low or too high, please check the battery voltage.

3. VERY IMPORTANT! Because different transmitter has different throttle range, you need to use the “Throttle Range Setting Function” to calibrate the throttle range. Please read the instructions on page 1------

“Throttle Range Setting”.

Specification

Class

80A

Model

FLYFUN-80-HV

100A FLYFUN-100-HV

Wiring Diagram

Cont.

Current

80A

100A

Burst Current

(>10s)

100A

120A

BEC Output

N/A

N/A

Battery Cell

Lipo

5-10

5-12

NiMH

15-30

15-36

User

Programmable

Yes

Yes

Weight

125g

112g

Size

L*W*H

88*55*18

88*55*18

Alert Tone

1. Input voltage abnormal alert tone: The ESC begins to check the voltage of battery pack when it is power on, if the voltage is not in the acceptable range, such an alert tone emits

: “beep-beep-, beep-beep-, beep-beep-” (Every “beep-beep-” has a time interval about 1 second)

2.

Throttle signal abnormal alert tone: When the ESC can’t detect the normal throttle signal, such an alert tone emits: “beep-, beep-, beep-”.

(Every “beep-” has a time interval about 2 seconds)

3. Throttle stick is not at its bottom position alert tone: When the throttle stick is not in the bottom (lowest) position, a very rapid alert tone emits

: “beep-, beep-, beep-”. (Every “beep-” has a time interval about 0.25 second.)

Protection Function

1. Start up protection: If the motor failed to start up in 2 seconds, the ESC will cut off the output power. In this case, the throttle stick MUST be moved to bottom again and then to restart the motor. (Such a situation happens in the following cases: The connection between ESC and motor is not reliable, propeller is blocked, gearbox is damaged, etc.)

2. Over-heat protection: When the temperature of ESC is higher than a factory-preset value, the ESC will gradually reduce the output power.

3. Throttle signal lost protection: The ESC will reduce the output power if the throttle signal is lost for 1 second, further lost for totally 2 seconds will cause its output to be completely cut off.

Note: There are 2 control wires on the HV controller. The longer one is close to the positive battery wire, which is connected with the receiver, and the shorter one is close to the negative battery wire, which is used to connect the program card to set the programmable parameters of the controller.

Anti-Spark Circuit

There is a pair of bullet connectors and a thin red wire attached with the positive input wire (red color, thick) of the ESC. They are used to eliminate sparks when the battery pack is connecting with the ESC. Please use it in the following sequence:

1. Disconnect the bullet connectors on the positive input wire (red color, thick) of the ESC.

2. Connect battery wires to the ESC.

3. Connect the bullet connectors on the positive input wire (red color, thick) of the ESC as soon as you hear the special tone

“♪123”.

Normal Startup Procedure

Switch on the Connect the battery transmitter, and then move the throttle stick to bottom position pack to ESC, a special tone “ 123” will emits, means the power supply is OK

Several “beep-” tones emit to represent the cells quantity of the lithium battery pack

When self-test is finished, a long

“beep

— ” tone emits

Ready to go flying now

Please note that we use a special way to represent the cells quantity of a lithium battery pack: 1 long “beep—” = 5 short “beep-”.

For example, 2 long

“beep—” plus 2 short “beep-” (Beep—Beep—BB) means a 12 cells lithium battery pack, 1 long “beep—” plus 1 short

“beep-” (Beep—B) means a 6 cells lithium battery pack, and so on.

Feature Explanation

1. Brake:Brake Enabled / Brake Disabled, default is Brake Disabled

2. Battery Type:Li-xx(Li-ion or Li-po) / Ni-xx(NiMh or Nicd),default is Li-xx.

3. Low Voltage Protection Mode(Cutoff Mode):Soft Cutoff (Gradually reduces the output power) or Hard Cutoff (Immediately stops the output power), default is Soft Cutoff.

4. Low Voltage Protection Threshold(Cutoff Threshold):Low / Medium / High, default is Medium.

 For Li-xx battery,the cells quantity of a battery pack is calculated automatically or set manually. Low / Medium / High cutoff voltage for each cell is: 2.6V/2.85V/3.1V. For example: 10 cells Lipo, when “Medium” cutoff voltage is set, the cutoff voltage is:

2.85*10=28.5V.

 For Ni-xx battery, low / medium / high cutoff voltages are 0%/45%/60% of the startup voltage (i.e. the initial voltage of the charged battery pack), 0% means the low voltage protection function is disabled. For example:20 cells NiMH battery, fully charged voltage is

1.44*20=28.8

V, when “Medium” value is set, the cutoff voltage is: 28.8*45%=12.96V。

5. Start Mode:Normal /Soft /Super-soft, default is Normal startup.

Normal is suitable for fixed-wing aircraft. Soft and Super-soft are suitable for helicopter. The initial speed of Soft and Super-soft mode is very slow so it will take 3 seconds (Soft startup) or 6 seconds (Super-soft startup) from zero speed to full speed. But if the startup process is completed (i.e. The motor is running), then the throttle is closed (that means the throttle stick is moved to bottom position at 0% throttle) and opened again (throttle stick is moved upwards) within 3 seconds, the restart will be temporarily changed to normal mode to get rid of the chances of crash caused by slow throttle response in aerobatic fly.

6. Timing:Low / Medium / High, default is Low.

In normal cases, Low or Medium timing is suitable for most motors. In order to get higher speed, please try the High timing value.

Note: After you changing the timing setting, please test your RC model on ground before taking off.

Throttle Range Setting Throttle range should be reset when a new transmitter is being used

Switch on the transmitter, and move the throttle stick to top position

Connect the battery pack to the ESC, and then wait for about 2 seconds

“Beep-beep-” tone emits, which means the highest point of the throttle range has been correctly confirmed

Move the throttle stick to the bottom position, and then several “beep-” tones emits to represent the number of Lipo battery cells

Trouble Shooting

Trouble

After power on, motor can’t work, no sound is emitted

After power on, motor can’t work, such an alert tone emits:

“beep-beep-, beep-beep-,beep-beep-”

(Every “beep-beep-” has a time interval about 1 second)

After power on, motor can’t work, such an alert tone emits:

“beep-, beep-, beep- ”(Every “beep-” has a time interval about 2 seconds)

After power on, motor can’t work, such a alert tone emits:

“beep-, beep-, beep-” (Every “beep-” has a time interval about 0.25 second)

Possible Reason

The connection between battery pack and ESC is not OK

Input voltage is abnormal, too high or too low

Throttle signal is abnormal

Throttle stick is not in its bottom position (Lowest position).

A long “Beep-” tone emits, means the lowest point of the throttle range has been correctly confirmed.

Action

Check the power connection.

Replace the connector.

Check the voltage of battery pack

Check the receiver and transmitter

Check the cable of throttle channel

Move the throttle stick to bottom

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Manual of Sensorless Brushless Speed Controller

HW-SM002DUL-20130610

After power on, motor can’t work, a special tone “ ” emits after 2 beep tones (beep-beep-)

The motor runs in opposite direction

The motor stop running while in working state

The direction of throttle channel is reversed, so the ESC has entered the program mode

The connection between ESC and the motor need to be changed.

Throttle signal is lost

ESC has entered Low Voltage

Protection mode

Set the direction of throttle channel correctly

Swap any two wire connections between ESC and motor

Check the receiver and transmitter

Check the cable of throttle channel

Land RC model as soon as possible, and then replace the battery pack

Some Connections are not reliable Check all the connections: battery pack connection, throttle signal cable, motor connections, etc.

2. Select Programmable Items

Now you ’ll hear 9 tones in loop. When a long “beep—” tone emits, please move the throttle stick to bottom position to enter the

“Startup Mode” item.

3. Set Item Value (Programmable Value)

“Beep-”, wait for 3 seconds; “Beep-beep-”, wait for another 3 seconds; then you’ll hear “beep-beep-beep”, move the throttle stick to top position, then a special tone

Startup ”

” emits, now you have successfully set the “Startup Mode” item to the value of “Super-soft

4. Exit Program Mode

After the special tone “ ”, move the throttle stick to bottom position within 2 seconds.

Program The ESC With Transmitter Stick (4 Steps)

1. Enter program mode

2. Select programmable items

3. Set item value (Programmable value)

4. Exit program mode

1. Enter program mode

1. Switch on transmitter, move throttle stick to top position, and then connect the battery pack to

ESC

2. Wait for 2 seconds, the motor will emit special tone like “beep-beep-”

3. Wait for another 5 seconds, special tone like

“ ” emits, which means program mode is entered

2. Select programmable items

After entering program mode, you can hear 9 tones in a loop in the following sequence. If you move the throttle stick to bottom within 3 seconds after one kind of tones, then this item will be selected.

1. “beep” Brake (1 short tone)

2.

“beep-beep-”

Battery type (2 short tone)

3. “beep-beep-beep-” Cutoff mode (3 short tone)

4.

“beep-beep-beep-beep-” Cutoff threshold (4 short tone)

5. “beep—” Startup mode (1 long tone)

6.

“beep—beep-”

Timing (1 long 1 short)

7.

“beep—beep-beep-” Lipo battery cells (1 long 2 short)

8.

“beep—beep-beep-beep-” Set all to default (1 long 3 short)

9.

“beep—beep—” Exit (2 long tones)

R

emark: 1 long “beep” = 5 short “beep-”

How To Use The Program

Card

1. Connect the battery

(4.8Vto 6V) to the port marked with “BATT”.

2. Connect the programming lead (shorter control wire) to the port marked with

“BEC”.

3. Connect the main battery pack to the ESC.

Please note the above connection sequence cannot be reversed.

Now t he “Music/Lipo cell” item only means the cells quantity of the lithium battery pack. ( ● = LED is lighting)

LED Lipo Cells LED

D

C

B

A

○ Auto detect

D

C

B

A

Lipo Cells

○ 9 CELLS (33.3V)

3. Set item value

You will hear tones in loop. Set the value matching to a tone by moving the throttle stick to top when you hear the tone , then a special tone “ ” emits which means the value is set and saved. (Keeping the stick at top, you will go back to step 2 and you can select other items;

4. Exit program mode

There are 2 ways to exit program mode.

1. In the step 3, after

● Auto detect

○ Auto detect

● Auto detect

○ 5 CELLS (18.5V)

Moving the stick to bottom within 2 seconds, you will exit the programming mode directly) special tone “ ”,

○ ● ○ ● 6 CELLS (22.2V)

● 10 CELLS (37.0V)

○ 11 CELLS (40.7V)

● 12 CELLS (44.4V)

○ Auto detect

● Auto detect

Tones

Items

Brake

Battery type

Cutoff mode

Cutoff threshold

Startup mode

Timing

Lipo cells quantity beep-

1 short tone

Off

Soft Cutoff

Low

Normal

Low beep-beep-

2 short tones

On

Li-ion / Li-Po NiMH / NiCd

Hard Cutoff

Medium

Soft

Medium

3 short tones

High

Super soft

High

N short tones

N beep tones represent N cells (N

≤ 4 means “Auto Detect”) move throttle stick to the bottom within 2 seconds.

2. In step 2, after the tone

“beep—beep—”

(Item #9), move throttle stick to the bottom within 3 seconds.

Note

:

1. It very important to set the Lipo battery cells quantity correctly, otherwise the ESC will mistakenly calculate the cut off voltage.

2. In

“Lipo cells quantity” setting process, 1 long “beep—” = 5 short “beep-”. For example, 2 long “beep—” plus 2 short “beep-” means a 12 cells lithium battery pack, 1 long “beep—” plus 1 short “beep-” means a 6 cells lithium battery pack.

3. If you are using lithium battery pack, you’d better set the “Lipo cells quantity” manually. The voltage of a full charged lithium battery pack is different from that of a discharged battery pack, the more cells a battery pack has, the more difficult for the ESC to automatically detect the cells quantity accurately.

An Example about ESC Programming

In the following example, we set the Startup Mode to “Super-soft”, i.e. value #3 of the programmable item #5

1. Enter Program Mode

Switch on transmitter, move throttle stick to top, connect battery packs to receiver and ESC, wait for 2 seconds,

“beep-beep” tone emits. Then wait another 5 seconds, a special tone “ ” emits, that means the ESC is in the program mode.

○ 7 CELLS (25.9V)

● 8 CELLS (29.6V)

○ Auto detect

● Auto detect

Accessory: RPM Sensor

The RPM sensor is an accessory of the high voltage speed controller.

Function

It detects the voltage changes at the wires of brushless motor, and then outputs the RPM signal. This RPM sensor can work with some speed control systems for helicopters. And one of its typical applications is to work as the RPM sensor for V-Bar system made by Mikado

(www.mikado-heli.de).

Specifications

1. Size: 23mm(L)*10mm(w)*2mm(H)

2. Weight: 6g (Input and output wires are included)

3. Working voltage: 3.5V to 8.4V(1S to 2S Lipo)

4. Current: 1 to 5mA

5. Voltage range of the motor wires: 2 to 14S Lipo

6. RPM range (for 2 poles brushless motor): 1000rpm to 300000rpm

7. Working temperature: 0 to 50 Celsius degree or 32 to 122 Fahrenheit degree

How to Use

The lead A and lead B is connected to any 2 wires of the brushless motor (Do not need to consider about the polarity). The lead C is a three color wires with a connector at the end, the black wire is the ground wire, the red wire is connected to 3.3V or 5V to supply the sensor, and the white wire outputs RPM signal.

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