Castle Creations Hydra 120 User manual

HYDRA 120 & 240 User Guide Page 1of 5Rev 8-date 04/11/077
This document, HYDRA™ software, and HYDRA PCB layout are all Copyright 2004-2007 by Castle Creations, Inc.
HYDRA 120 & HYDRA 240 OPERATION MANUAL
Thank you for purchasing the most technologically advanced brushless electronic
speed controller in the world for RC boats! Please take the time to read over these
instructions to ensure you get the most from your HYDRA brushless speed control,
and enjoy years of trouble-free operation.
1.0 Features of the HYDRA™ :
•Extremely Low Resistance (120 is .00043 ohms; 240 is .00022 ohms )
•Up to 120 or 240 Amps continuous current
•Water cooled heat sinks (see section 6.0 below)
•Massive 10 gauge wire on Hydra 120 and double 10 gauge wires on the
Hydra 240.
•12 cells (3s lipo) MAX with BEC
•Six to twenty cells, or 2 to 6 cell Lithium Polymer packs
•BEC (3A) provides power to receiver and
servo -eliminates separate receiver battery
•User Programmable Features:
·Reverse Type
·Reverse Throttle Amount
·Low voltage cutoff (LiPo safe)
·Timing Advance
·Starting Power
•Safe “power on” arming program helps prevent motor from accidentally
turning on. Always use extreme care with high power systems.
•Auto shut down when signal is lost or radio interference becomes severe
2.0 Making Connections on your HYDRA™ speed control
Tools required: Parts required:
Wire cutters Rosin core electrical solder
Wire stripper (optional) Battery connector
Soldering iron (30-40W)
2.1 Adding a battery connector to your HYDRA™:
The battery connector must be added to the power side of the controller (black
capacitors, receiver connector, and red and black wire side). The red wire is the
positive (+) lead, and must match up to the positive lead from your battery. The black
wire is the negative (-) lead, and must match up to the negative lead from your
battery. The polarity MUST BE CORRECT or the controller will be damaged from
reversed polarity.
The Hydra 240 has two SETS of input and output wires. We recommend using a
separate connector for each c
onnection to ensure maximum current capacity. Make
sure and connect the entire battery pack to both input wire sets of the Hydra 240.
Do not connect half of the pack to one input, this will lead to operating problems from
potential voltage / current imbalances.
Strip just enough insulation off of the battery wires to solder on your battery
connector to the controller leads. After the connector is soldered and insulated
(shrink tubing or electrical tape) check it ONE MORE TIME to make sure the polarity
is correct before you plug in a battery.
2.2 Plugging in motor leads:
With a brushless system, there is no polarity on the MOTOR side of the controller.
Simply solder the three leads to your motor (recommended) or solder your choice
of
connectors to the motor and controller leads. After the throttle calibration routine
below –if the motor runs backwards with foreword throttle, simply swap any two of
the motor/controller connections and it will reverse the rotation of the motor.
The Hydra 120 and 240
controllers are designed to control one motor. Do not
attempt to drive two motors with the Hydra 240. Connect the dual outputs of
the 240 to a single motor’s leads.
2.3 Connecting to the receiver:
Connect the receiver lead (the three color wires with a connector on the end) to the
throttle channel on your receiver (usually channel 2). Do not connect a battery to the
receiver, as the HYDRA™ will supply power to the receiver and servo through the
receiver connector. If you are using more than 12 cells, or 3s Lipo packs, the BEC
must be disabled on the controller. Disable the BEC by removing the red wire from
the receiver connector.
3.0Calibrating the HYDRA™ to YOUR transmitter:

HYDRA 120 & 240 User Guide Page 2of 5Rev 8-date 04/11/077
This document, HYDRA™ software, and HYDRA PCB layout are all Copyright 2004-2007 by Castle Creations, Inc.
IMPORTANT NOTE: Calibration is required for the very first use of the
HYDRA™ or whenever used with a new/different transmitter.
The HYDRA™ contains a throttle calibration feature that you'll want to use the first
time you power it up with a new/different transmitter. Performing this exercise will
teach the controller how your transmitter works.
•Disconnect battery
•Hold full throttle on your transmitter
•Connect battery
•HYDRA™ flashes LED and rings once
•Wait 2 seconds
•HYDRA™ flashes LED and rings 4 times indicating full throttle measured
•HYDRA™ flashes LED while beeping, indicating it's time to push full brake
•Push full brake
•Wait 1 second
•HYDRA™ flashes LED and rings 4 times indicating full brake measured
•HYDRA™ flashes LED while beeping indicating its time for neutral
•Relax trigger to neutral (center)
•Wait 1 second
•HYDRA™ flashes LED and rings 4 times indicating neutral measured
•Wait for 1 second
•HYDRA™ will flash LED and ring twice indicating that it is armed
3.1Programming Mode
Programming the HYDRA™ is as simple as answering a few questions. The
HYDRA™ asks questions by flashing a setting number, followed by the possible
setting values. There are five settings that can be programmed in the HYDRA™:
1) Reverse Type,
2) Reverse Throttle Amount,
3) Cutoff Voltage,
4) Timing Advance,
5) Starting Power.
You must answer “yes” or “no” to the setting values as they are presented by the
HYDRA™. When you enter programming mode the controller will emit a sequence
of beeps and LED flashes that tell you which programming step you are in. There are
two parts to the beep sequence. The first set of beeps indicates the ‘Setting’ Number
(e.g., Cutoff voltage type), and the second set of beeps indicates a Setting Value (e.g
2 cell LiPo). Answering “no” to a Setting Value will cause the HYDRA™ to ask for
the next Value. Answering “yes” to a Setting Value will store that setting in the
HYDRA’s™ permanent memory. After a setting is stored, the HYDRA™ will
automatically continue to the next setting until all settings have been stored. NOTE:
If you answer “no” to all Setting Values for a particular Setting Number, the HYDRA
™
will keep whatever value had been previously programmed. Only by answering “yes”
to a Setting Value will the HYDRA™ store/change that value.
When answering a question, y
ou will need to move the trigger to the yes (full throttle)
position or the no (full brake) position and keep it there for about 5 seconds. When
the HYDRA™ has accepted your answer it will confirm your reply by flashing the
LED and emitting a beeping tone. Release the trigger allowing it to go to Neutral to
confirm that you are ready for the HYDRA™ to ask the next question.
You are not required to continue through all five programming options. For example,
if you wish only to change the Reverse Type (option 1) then after programming that
setting you can disconnect power from the HYDRA™ and you’re ready to run.
Disconnecting the controller in the middle of programming simply retains the values
for the remaining programming options that were previously set up.
3.2.1 Programming Example
The following is a simplified example demonstrating how to “skip” through a program
section, how to set a program option, and how to terminate programming early. In
this example we will: 1) skip (e.g. do not change) Reverse Type setting, 2) change
Reverse Throttle Amount to 12.5%, and 3) terminate programming after this option.
3.2.2 Entering Programming mode
•Disconnect battery
•Hold full throttle on your transmitter
•Connect battery
•HYDRA™ flashes LED and rings once
•Wait 2 seconds
•HYDRA™ flashes LED and rings 4 times indicating that it is ready for
CALIBRATION mode
•Continue to hold full throttle
•HYDRA™ flashes LED while beeping
•Wait 8 seconds
•HYDRA™ flashes LED and rings 4 times
•HYDRA™ flashes LED while beeping indicating that you are in
PROGRAMMING mode
•Let trigger go neutral (center)
At this point the HYDRA™ will be flashing/beeping the following sequence:
Beep –Pause –Beep… and then Repeats
This indicates that you are at Question 1 and it is asking to accept/reject Value 1.

HYDRA 120 & 240 User Guide Page 3of 5Rev 8-date 04/11/077
This document, HYDRA™ software, and HYDRA PCB layout are all Copyright 2004-2007 by Castle Creations, Inc.
3.2.3 Skipping Programming Sections –No change required
Looking at the table on the last page you can see that Question 1 is ‘What
reverse/brake type do you want?’ and that Value 1 is ‘No Reverse’. We don’t want to
change the current value of this option, so we will say no to each value thereby
skipping the programming option.
•Apply full brake for 1 second (NO)
•HYDRA™ flashes RED LED and rings 4 times, indicating that it has
accepted your answer
•HYDRA™ flashes/beeps: ‘Beep –Pause –Beep -Beep’ (Question 1,
Value 2)
•Apply full brake for 1 second (NO)
•HYDRA™ flashes LED and rings 4 times, indicating that it has accepted
your answer
At this point you will have answered no to both of the questions in Section 1, so the
HYDRA™ will move on to Section 2 without modifying the currently stored value.
3.2.4 Changing a Program Option
•HYDRA™ flashes/beeps: ‘Beep –Beep –Pause –Beep’ (Question 2,
Value 1)
From the Table on the last page, Question 2 is ‘Reverse Throttle Amount’
and Value 1 is ’12.5%’. This is the value we want to accept.
•Apply full throttle for 1 second (YES)
•HYDRA™ flashes LED and rings 4 times, indicating that it has accepted
your answer.
•At this point the HYDRA™ will move on to Setting Number 3.
3.2.5 Terminating Programming Early
In this example, we do not need to change any of the remaining
programming options, therefore we can terminate the programming routine by
disconnecting the battery from the HYDRA™. This leaves the remaining
programming options at their previously stored values.
3.2.6 A Word About Cutoff Voltages
If you are running NiCad or NiMH cells, the default cutoff voltage of the HYDRA™
(5.0V) is normally what you should use, and anything else in the programming is up
to your personal preference to change, so you are ready to run!
** IMPORTANT NOTE: Lithium Polymer Users **
If you are using Lithium Polymer (Li-Po) batteries, DO NOT operate your boat with
the factory default Cutoff Voltage. You must change the Cutoff Voltage BEFORE
running your boat.
4.0 Troubleshooting:
Everything is hooked up correctly, the BEC (receiver and servo) works, but the
throttle does not work.
The controller is not seeing the four seconds of neutral throttle and is not arming. Try
moving your throttle trigger slightly in each direction to arm the controller or follow
the calibrating function Section 3.1 above. You may also check to make sure that
your endpoint adjustments on your radio (if it has them) are set all the way open
(both top and bottom, are furthest from zero).
Every time I throttle all the way up, the controller “cuts off” after a few
seconds, even with fresh charged batteries.
The
controller will automatically shut down the motor if the battery voltage falls below
the programmed voltage cutoff (factory preset at 5.0V) for more than half a second.
This is to protect your boat from a loss of control caused by too low a voltage at the
receiver. If the cutoff is kicking in with fresh charged batteries, it means that the
voltage is dropping very quickly. This is usually an indication of a motor that is
drawing too much current for the batteries to handle. Try using a smaller prop on the
motor, or using batteries with a higher rating.
Nothing seems to work, receiver and servos are dead, and the throttle is
dead.
Check all connections to ensure that they are correct, and that the polarity (+/-)
battery connections are correct. If everyth
ing is correctly connected, and the receiver
and servos still do not work, contact the dealer where you purchased your HYDRA
™
or Contact Castle Creations directly. (See Section 6.0 below)
5.0 Intended Use
The HYDRA™ is intended for exclusive use with boats only. Use in any other
vehicles or aircraft is not covered by warranty and will not be supported by Castle
Creations, Inc.

HYDRA 120 & 240 User Guide Page 4of 5Rev 8-date 04/11/077
This document, HYDRA™ software, and HYDRA PCB layout are all Copyright 2004-2007 by Castle Creations, Inc.
6.0 Water Cooling Tubing
Users must provide their own water cooling tubing.
HYDRA 120 Attach the input and output tubes to one end of the controller. Cut a
section approximately 3.75” long and use it to connect the tubes at the opposite end
of the Hydra. Make sure the flexible tubes curve gently with no tight bends. Please
see the diagram below for reference.
HYDRA 240 There are 4 aluminum cooling tubes on the HYDRA 240TM. You
must make three crossover sections of plastic or silicon tubing that are
approximately 3.75-4” long. Connect the input/output tubes to the two aluminum
tubes on the top of the controller closest to the CASTLE text / motor wires. Connect
the bottom controller tubes on the motor side together with a 3.75” inch length of
tubing. Connect the top left tube on the battery side of the controller to the bottom
right tube on the battery side with a 3.75” tube. Now connect the remaining tubes
on that side with a slightly longer tube. The water should flow into the controller on
the top board, flow to the bottom board, then to the other side of the top board, down
to the remaining side of the bottom board and then out of the controller.
Please see the diagram below for reference.
7.0 Contact/warranty information:
Your HYDRA™ is warranted for one (1) year from date of purchase to be free from
manufacturing and component defects. This warra
nty does not cover abuse, neglect,
or damage due to incorrect wiring, over voltage, or overloading.
Each controller is tested for proper operation before it leaves our shop.
If you have any questions, comments, or wish to return your HYDRA™ for warranty
or non-warranty repair/ replacement contact Castle Creations at:
Castle Creations Inc.
235 S. Kansas Ave
Olathe, KS 66061
Tel: [phone] Email: [email protected]
Fax: [phone] Website: http://www.castlecreations.com

HYDRA 120 & 240 User Guide Page 5of 5Rev 8-date 04/11/077
This document, HYDRA™ software, and HYDRA PCB layout are all Copyright 2004-2007 by Castle Creations, Inc.
PROGRAMMABLE FEATURES
NOTE: Factory Defaults are indicated by asterisk (*)
Question Value Description
1) Brake/Reverse
Type *1) No Reverse No reverse function.
2) Forward to Reverse This setting makes the boat operate freely in
forward and reverse
2) Reverse Throttle
Amount 1) 12.5%
This setting makes your
maximum reverse speed
equal to 12.5% of full
power
*2) 25% This setting makes your maximum reverse speed
equal to 25% of full power
3) 50% This setting makes your maximum reverse speed
equal to 50% of full power
4) 100%
This setting makes your
maximum reverse speed
equal to 100% of full
power
NOTE: when stetting Lipo cutoff voltage follow your battery manufacturer’s
recommendations.
Question Value Description
3) Cutoff Voltage 1) minimal cutoff Nicad/NiMH cells
*2) 5V cutoff Nicad/NiMH cells
3) 6V cutoff 2 cell Li-Po
4) 7.2V cutoff
4) 9V cutoff 3 cell Li-Po
5) 12Vcutoff
Use this setting at your
own risk! Damage to the
controller as a result of
using a 4-
cell LiPo pack is
not covered by the
manufacturer’s warranty.
4) Timing Advance 1) Low Max efficiency/runtime.
*2) Normal Balance power/runtime.
3) Race More power/less runtime.
Use at your own risk! 4) Extreme Max power. Most smoke.
No warranty.
5) Starting power *1) Low
2) Normal
3) High
Increase the value of this
setting if your model has
difficulty starting smoothly
under low power.