HobbyStar 80A User manual

Product Manual
WWW.HOBBYSTARLABS.COM
Copyright © 2016 HobbyStar
Sensored/Sensorless Brushless Speed Controller
for Car or Truck
Thank you for your purchasing this Brushless Electronic Speed Controller (ESC). This electronic
speed controller is specifically designed for operating Sensored/Sensorless brushless motors. High
power systems for RC models can be very dangerous and we strongly suggest that you read this
manual carefully. We have no control over the correct use, installation, application or maintenance
of these products, thus no liability shall be assumed nor accepted for any damages, losses or costs
resulting from the use of this item. Any claims arising from the operating, failure or malfunction, 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
obligation for compensation is limited to the invoice amount or product in question.
Features:
Enhanced throttle response, excellent acceleration, strong brakes and throttle linearity
Advanced software interface for setting up and firmware updates.
Uses LCD or LED program card for adjustments.
Multiple protection features: Low voltage cut-off protection, over-heat protection and
throttle signal loss protection
Compatible with brushless sensored/sensorless motors.
Setup
Please check all connections carefully and make sure they are connected properly.
Sensored Mode:
When using a Sensored Brushless motor, the Blue motor wire A, the Yellow motor wire B and the
Orange motor wire C of the ESC must be connected with the Sensored motor wire A,B,C
respectively. It is necessary to connect the Sensor wire to the "Sensor" socket on the ESC. It is
important to not alter the order of motor wires when using with a sensored motor.
Sensorless Mode:
When using a Sensorless Brushless motor, the Blue motor wire A, the Yellow motor wire B and the
Orange motor wire C of the ESC can be connected with the motor wires in any order. If the motor
runs in the opposite direction, please swap any two wire connections.
Connection to the Receiver
Black wire RX-
Red wire RX+6.0V
White wire RX-Signal
LEDs:
Sensored/sensorless function
When the Power wires on the ESC are connected with the battery pack, the ESC can automatically
identify the motor type (Sensored/Sensorless) via indicated LEDs. Sensored cable must be
removed for ESC to operate in sensorless mode.
Throttle Range Calibration
The ESC must be calibrated when used for the first time, and any time a new radio/receiver is
used.
For the first time using transmitter or changing the transmitter you must set up Throttle Range
Calibration.
1. Switch off the ESC, then connect ESC to battery and turn on the transmitter; set the EPA/ATV
(travel) value of the throttle channel to the maximum setting in both directions (can be 100%,
125%, 150% etc. depending on radio).
NOTE: Some radios must have throttle channel set to REV (e.g. Futaba, Flysky).
NOTE: If your radio is equipped with ABS braking it must be disabled for calibration.
2. Hold the "set" button down and turn on ESC while still holding the "set" button. After about 4
seconds the LED will turn SOLID BLUE. Release the "set" button, and immediately apply full
throttle and hold it. The LED will FLASH RED and then turn SOLID RED. Motor will beep.
3. Immediately apply full brake (do not stop at neutral). The LED will FLASH BLUE and then turn
SOLID BLUE. Motor will beep.
4. Return throttle to neutral position. RED and BLUE LEDs will flash, and then turn solid and then
off. Motor will beep. Throttle has been calibrated.
5. Turn the ESC back ON. The ESC is now ready to use.
Programmable Items and default settings:
Default settings are shown in the grey boxes.
Programmable
Items
Programmable Value
1
2
3
4
5
6
7
8
9
Cut-off Voltage
2.6V/cell
2.8V/cell
3.0V/cell
3.2v/cell
3.4V/cell
NO-Cut Off
Running Mode
Forward
w/o
Reverse
Forward
with pause
then
Forward
/Reverse
Motor timing
Very Low
Low
Normal
High
Very High
Initial
Acceleration
Low
Medium
High
Very High
Throttle percent
Reverse
20%
30%
40%
50%
60%
70%
00%
90%
100%
Throttle Limit
0%
20%
30%
40%
50%
60%
70%
80%
90%
Percentage
Braking
10%
20%
30%
40%
50%
60%
70%
80%
100%
Percentage Drag
Brake
0%
4%
8%
12%
15%
20%
25%
30%
Motor Rotation
Normal
Reverse
Neutral Range
2%
3%
4%
5%
6%
10%
Sensored/Sensorless brushless ESC general information
1. Cutoff Voltage
Automatically detects number of cells
ESC automatically detects number of cells in battery pack. You can program the cut-off voltage as
an individual cell voltage. For example, if you set cut-off to a 3.2v. cell, a 2S LiPo pack will cut-off at
a total pack voltage of 6.4v. Cut-off can be programmed via program card or PC software.
When using NiMH or NiCd batteries you do not need to set a cutoff voltage to protect the batteries.
If you are using more than 6-cell NiMH or NiCd batteries, you must adjust the cutoff voltage. For
example if you are using an 8-cell pack of NiMH batteries, you would use a cutoff of 5.6V volts (8 x
Function
LED
LED Status
Low voltage of the battery
Red LED
Blinking
Over-heat of the ESC and motor(95'C)
Blue LED
Blinking
Sensored motor
Blue and Red LED
ON
Sensorless motor
Blue LED
ON

0.7V = 5.6V). When the voltage of the batteries packs is within 8.4-12.6V, the ESC will
automatically identify 3S LiPos. When the voltage of the batteries packs Is less than 8.4V, the ESC
will automatically identify 2S LiPos. When the voltage of the batteries packs is within 8.4-14.8V, the
ESC will automatically identify 2-4S LiPos. When the voltage of the batteries packs is within 21-
25.2V, the ESC will automatically identify 5-6S LiPos.
Customized voltage Cutoff
For NiMH or NiCd Batteries, you can select a starting cutoff voltage of 4, 5, 6, 9 or 12 volts. Using
the up/down to the right of the voltage you can increase the voltage stepping up 0.1V between the
selectable settings.
When using any Lithium or Ml (A123) batteries, they must not be discharged to less than 3.0V per
cell.
Running Mode
Forward w/o Reverse
This is a Race setting - Reverse is disabled.
Note: Most tracks will not allow racing with reverse enabled.
Forward with pause then Reverse: (DEFAULT)
General bashing around (FUN) or racing if reverse is allowed for the event. The Electronic Speed
Controller requires 2 seconds of continuous neutral from the transmitter prior to allowing reverse to
operate.
Note: There is automatic protection within the ESC. If while traveling in reverse,
you pull the trigger to go forward, only after you have stopped and returned the
trigger to neutral will reverse become available. This is to help prevent serious
damage to the drive train.
Forward/Reverse
If this option is selected, the car will be able to go forward and backwards but will not have brakes.
ESC reverse operation
If you need to engage reverse, apply brakes and return throttle to neutral after car has come to a
complete stop. Wait at least 2 seconds and then push trigger to full brake position to activate
reverse.
Motor Timing - This option affects the power band and efficiency (run time) of an electric motor.
The default is Normal and is a good starting point to deliver power and provide good run time.
Very Low - Provides maximum efficiency with less power. Higher timing produces significantly
more power but at the expense of efficiency (less run time) and typically the motor will generate
more heat. Each brushless motor will respond to timing differently. Good for running around on
paved or harder surfaces, and racing with high KV rated or low-turn motors.
Low - Provides power for running through soft surfaces, having fun and longer run time.
Normal (Default) - Good mix of power and efficiency using any motor.
High - More power than efficiency, so run time will be reduced, and you should be monitoring
motor heat. The higher KV or lower turn motors will generate heat quickly using this setting. A safe
high temperature range is 165F to 180F (74° - 82° Celsius); going higher may damage your motor.
Very high - This is maximum power and must be used with caution.
Note: Any motor has the potential to overheat in this setting. Frequently check the motor
temperature and make sure you're not operating higher than 165° and 180° Fahrenheit (74° - 82°
Celsius), which may damage your motor or your Electronic Speed Controller (ESC).
Initial Acceleration - Use this to limit the initial power that is sent to the motor when starting
from a complete stop.
Using the Low option, the vehicle will launch very slowly and provide the longest run times. When
using the High choice, you will have wheel-spinning acceleration at the cost of run time. This is
also very tough on the batteries as the amperage draw can be very high. If your vehicle cuts out,
hesitates or loses radio control, you should consider setting this at a lower value.
Low - Using this option will provide longer run times and is easiest on the batteries. It is a good
choice for beginners.
Medium - Requires more from your batteries, and is good for low traction surfaces.
High - This option will provide full acceleration and requires stout batteries to supply the load
required in this setting.
Very high - This option will provide full acceleration and requires stout batteries to supply the
load required in this setting.
Throttle Percent Reverse - Use this to limit the power available using reverse throttle. The
lower the percent or level the less speed will be available in reverse.
20%, 30%, 40%, 50%, 60%( Default), 70%, 80%, 90%, 100%
Throttle Limit - Use this to limit the power available using forward throttle.The lower the percent
the less forward throttle speed will be available.
0%(Default), 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%
Percentage Braking - Gives you the ability to have full control over the amount of brake your
vehicle will have.
10%, 20%, 30%, 40%, 50%(Default), 60%, 70%, 80%, 100%
Percentage Drag Brake - The drag brake function provides the driver a set percentage of
brake when you have the transmitter resting in neutral. This will create the feeling of a Brushed
Motor. Drag brake are used in racing to slow a vehicle as you let off approaching a corner versus
the driver having to push the brake at every corner. Try working with this to get a sense of how you
might use this for your track. If you are running on a high traction track with tight corners, a
stronger setting should work best. If you are running in an open area, you will find a smaller
percentage will result in better control. If you are running on slippery or dusty surfaces, you will
more than likely want to use the lowest option.
0%( Default), 4%, 8%, 12%, 15%, 20%, 25%, 30%
Motor Rotation Normal (default). Reverse
Neutral Range - This setting adjusts the amount of "Deadband" off neutral on the throttle trigger.
This is in milliseconds (MS) and is the amount of neutral when you pull the trigger. The smaller the
value, the less "Deadband" or movement is required off-center for the ESC to begin throttle
function. Using a higher value for this setting will provide a wider "Deadband."
2%, 3%, 4% (Default), 5%, 6%, 10%
BEC –BEC is adjustable via “11th”(hidden) option on LCD card or via Starlink US Link. 6V/8.4V
***VERIFY SERVO AND RX ARE RATED FOR HIGH-VOLTAGE, OTHERWISE DAMAGE TO
ESC, SERVO OR RX MAY OCCUR.***
How to use a PC to set up or update the firmware:
1. An LCD program card or a StarLink USB link is required to link the ESC to a PC via the
supplied USB cable. The desktop application can be downloaded from www.HobbyStarLabs.com.
2. Connect the LCD card or the StarLink to the PC via the USB cable, and connect the ESC
signal lead to the port marked "ESC" on the LCD card or the StarLink. Note: Make sure the black
wire from the ESC signal lead is aligned with the "- "on the ESC port on the LCD card or the black
mark on the StarLink.
3. Switch on the ESC, and launch the desktop application. You will now be able to read and
change the ESC settings and update firmware.
Note: If working with Windows 2000, you will be required to restart the PC before the USB
Adaptor gets connected and the small LED on the adapter turns from Red to Blue.
4. The ESC settings will be read when application is launched. If settings do not appear, press
the "Data" button to read the ESC.
5. When you are done making adjustments, click the "Apply” button, and settings will be saved to
the ESC. You do not need to hit "Apply" after every change. Note: When using an LCD card as a
stand-alone programmer, you must hit "OK" after every change for it to be saved to the ESC.
6. The "Firmware" option can be used to upgrade the ESC firmware if a new version is available.
Note: Firmware needs to be downloaded separately, and loaded via the "Firmware" option. The
application is not connected to the internet and does not search for or automatically download
updates.
7. The software is installed and ready for use now.
Please refer to the section above for a general overview and field-specific help. Take a moment to
review the selectable functions, and read the specific help text to become familiar with each of
them. To make configuration changes to a function, select the setting you want, and from the drop-
down menu select your new choice or option. When you are satisfied and finished with this
configuration, click the "SEND Settings" button located on the bottom of each tabbed page.
Connection: This section is displayed on every Tab. There are two icons; one for the USB
connection, the other indicates the Electronic Speed Control connection. They are Orange in color
when disconnected and Blue on connection.
Note: It is not recommended that you make changes to the "default" configuration without a full
understanding of a specific function and the reasons for the changes. The defaults were selected
as a direct result of the testing used to establish these settings. Changing of the configuration will
be at your own risk.
Read Settings: Use of this button will read the current Electronic Speed Control
(ESC) configuration and present it on the current tabbed page only.
Send Setting: Use of this button will send (write) the current selected configuration to the ESC
for the current tabbed page only.
Upgrade Firmware: Use of this button will begin the firmware upgrade process. A pop-up will
be displayed, and you need to select the location of the firmware update file. You may cancel this
process here without any effect to the ESC firmware.
After finding and selecting the file, the confirmation screen will then display. You may still cancel
the process at this time without any effect to the ESC firmware. If you select OK, the progress
status percentage of the upgrade will be displayed. Please do not unplug your computer or the
ESC while the upgrade is in progress, or damage to the ESC may result. If no problems were
encountered, OK will be displayed and the configuration redisplayed.
You are finished with the upgrade and you can re-configure the ESC or end the program.
If a problem is encountered and the upgrade fails, simply restart the upgrade process. If there
should be another failed upgrade, then close all other programs on your computer and possibly re-
download the file from the website.
Using the LED Program card
The Program card with LED display is easy to use and convenient to carry. All of the
programmable functions are shown on the program card.
1. Turn on the ESC, and plug the signal wire into the port on top of the card marked " ": After
2 seconds the card will turn on, and the first setting will be displayed. If the card does not turn on,
check the connections and try again.
2. If ESC is not connected to battery power, a separate power source will need to be connected
to the program card. Connect a 5.0-6.3V power supply (battery) to port marked " " with the
negative (black) wire aligned with the " " symbol.
3. The number on the left is the programmable item which is being displayed, and the number on
the right is the current setting. You can scroll through all the settings using the "Menu" button. To
make changes to a given setting, use the "Value" button to change the "number on the right"
setting. Press "OK" to apply the new setting to the ESC. NOTE: You must press "OK" after every
individual change or they will not be saved to the ESC.
4. Pressing the "Reset" button will restore all settings to default.