- Brushless Systems -


        III - Brushless System

              
2 - Sensored Brushless Systems

Those days, many manufactures provide brushless system for RC cars. Concerning the sensored brushless system, the number of manufacturer is quite reduced. The point here is competition. The sensored system is allowed in racing for the past year in some countries and will be allow in others the coming year. The rules name some equipments including LRP-Reedy, NOSRAM and TEAM NOVAK for the well known.

                       

 Nevertheless, others manufacturers, as Schulze, have ESC compatible with sensored motor.

   

We will focus on "legal" brushless system here. As say previously, LRP-Reedy, NOSRAM and TEAM NOVAK are the main manufacturers of those systems. The ESC and the motor work tougher in that case, manufacturers had developed motors in adequation with their ESC. The number of ESC is limited and some motors run with each ESC.

The sensored brushless ESC available are: (short list, more exist)

Castle Creations
Mamba Max Cells: 
6-12 NiCad/NiMH
2-3s LiPo
Continuous: 100 amps
Resistance: 0.0003 ohms
Brake: Proportional
Reversible: Yes - with lockout
Low Voltage Cut-off: Programmable
Size:
ESC overall: 1.9 x 1.3 x 1.2"
Weight (w/wires):
ESC: 2.5 oz (70.9 g)
Connector Type: Universal

Tuning guide

Mamba Max User Guide (pdf)
GM Racing
GM-Genius 95 SET button:
Numerous supplementary functions can also be programmed simply using the GMVIS Commander, PC RS232 interface or SET button:
Rotational speed limit (brushless motors only)
Timing: 0°, 7,5°, 15° or 30° (brushless motors only)
Soft-start
Current limiting
Current rise function at full-throttle
Brake minimum
Brake maximum
Start-up current limiting
Automatic brake
Frequency mode
Power curve (soft, linear, hard)
Automatic throttle
Full brake
Maximum reverse speed
Switched functions
ABS brake function

Mode:
Mode 1: Electric-powered model gliders, all models (forward with EMF brake), factory default setting
Mode 2: All models without brake and without reverse function (power model aircraft, model boats)
Mode 3: Model helicopters with speed regulation (governor moode)
Mode 4: Models with brake and reverse function (model car, model boat)

Specification
Operating voltage range 7.2 ... 14.8V (19.2V*)
Cell count, Ni-Cd, Ni-MH 6 to 12 (16*)
Cell count, Li-Po, Li-Io 2 to 4 (5*)
Cont. current (brushless motors) 70 A
Maximum motor current (10 sec.) 140 A
Temperature cut-off approx. 120° C
EMF brake programmable
Reverse function programmable
Soft-start programmable
Low-voltage power-down yes
Power-on pulse suppression yes
Pulse frequency 8 kHz
BEC receiver power supply approx. 5.5 V / 4 A peak
Max. BEC dissipated power at 20° C 2.5 W
OPTO optional
Dimensions excl. capacitors approx. 50 x 27 x 15 mm
Dimensions incl. capacitors. approx. 70 x 27 x 15 mm
Weight excl. cables approx. 33 g
Weight incl. cables approx. 70 g
Replacement for Order No. 94133
* with opto-coupler, Order No. 2894.3, and when using a four-cell receiver battery

 

GM-Genius 85 Description
- New software specially designed for model cars and boats, but also suitable for model aircraft.
- GM-Genius 85 and GM-Genius 100: splashproof case (sensorless operation only)
- New special brake software provides several different braking characteristics
- Automatic detection of brushed + brushless motors
- Automatic detection of motors with Hall sensors
- Unprecedented standard of control andstart-up characteristics with sensorless brushless motors
- Ideal for competition use >= 5 min.
- Optimised heat-sink for improved cooling (supplementary water-cooling possible with GM-GENIUS 50, 85, 90)
- Four drive programs, simple to set:
Modes 1 - 3 with forward / neutral / brake mode for competition use
Mode 1: for normal track conditions, with standard NiMH low-voltage power-down and active special brake software
Mode 2: for high-grip track conditions, for maximum acceleration and braking, with lower NiMH low-voltage power-down.
Mode 3: for slippery track conditions, with LiPo low-voltage power-down (optimised for four cells)
Mode 4: forward / neutral / brake / reverse, with standard NiMH low-voltage power-down
- All supplementary functions can also easily be programmed individually using the IDA programming system with Programmer, GMVIS-Commander(V2005) or PC (Windows 2000 or XP)
- Programmable supplementary functions such as automatic brake, maximum brake, maximum reverse speed, ABS, speed limiting, soft-start, minimum brake, full brake, automatic throttle, power curve, motor timing, current limiting, start-up current limiting, turbo and different braking characteristics.

Specification
Operating voltage range: 4.8 ... 14.8 V
Cell count, NiCd, NiMH: 4 - 12
Cell count, LiPo, LiIo: 2 - 4 (Mode 3)
Continuous current (brushless motors): 85 A
Max. motor current (10 s.): 170 A
Temperature cut-off: approx. 120° C
EMF brake: programmable
Reverse: programmable
Soft-start: programmable
Low-voltage power-down: yes
Power-on pulse suppression: yes
Pulse frequency: 8 kHz
BEC receiver power supply approx. 5.5 V / 4 A peak
Max. BEC dissipated power at 20° C: 2.5 W
OPTO: optional
Dimensions excl. capacitors approx. 48 x 40 x 20 mm
Dimensions incl. capacitors approx. 65 x 40 x 20 mm
Weight excl. cables approx. 75 g
Weight incl. cables approx. 105 g
Connector: G3,5
GM-Genius 80

SET button:
Numerous supplementary functions can also be programmed simply using the GMVIS Commander, PC RS232 interface or SET button:
Rotational speed limit (brushless motors only)
Timing: 0°, 7,5°, 15° or 30° (brushless motors only)
Soft-start
Current limiting
Current rise function at full-throttle
Brake minimum
Brake maximum
Start-up current limiting
Automatic brake
Frequency mode
Power curve (soft, linear, hard)
Automatic throttle
Full brake
Maximum reverse speed
Switched functions
ABS brake function

Mode:
Mode 1: Electric-powered model gliders, all models (forward with EMF brake), factory default setting
Mode 2: All models without brake and without reverse function (power model aircraft, model boats)
Mode 3: Model helicopters with speed regulation (governor mode)
Mode 4: Models with brake and reverse function (model car, model boat)

Specification
Operating voltage range 7.2 ... 12V
Cell count, Ni-Cd, Ni-MH 6 to 10
Cell count, Li-Po, Li-Io 2
Cont. current (brushless motors) 80 A
Maximum motor current (10 sec.) 160 A
empf. Motor: brushless 5.5 T
Temperature cut-off approx. 120° C
EMF brake programmable
Reverse function programmable
Soft-start programmable
Low-voltage power-down yes
Power-on pulse suppression yes
Pulse frequency 8 kHz
BEC receiver power supply approx. 5.8 V / 4 A peak
Max. BEC dissipated power at 20° C 2,5 W
OPTO optional
Dimensions excl. capacitors approx. 48 x 31.5 x 15 mm
Dimensions incl. capacitors. approx. optional
Weight excl. cables approx. 50 g
Weight incl. cables approx. 90 g
* with opto-coupler, Order No. 2894.3, and when using a four-cell receiver battery

 

Programmer for all Genius Regler Description
- Two-line LCD screen
- Simple method of reading out and programming the seventeen supplementary functions of GENIUS speed controllers
- Two memory facilities for storing various speed controller settings
- Servo test function for different cycle times: 3 ... 25 ms
- Automatic test facility for servos, e.g. for continuous testing, display or demonstration purposes. Variable test time for servotravel: 0.5 - 10 seconds.
- Receiver signal test function, indicates pulse width and cycle
- Internal LiPo battery voltage measurement
- Voltage measurement range 0 ... 30 V (resolution: 0.05 V)
- No-contact rotational speed measurement for propellers with 1 to 6 blades, with optional illumination for rev. counting even under difficultconditions.
- Dimensions: approx. 84 x 41 x 20 mm
- Weight approx.: 68g
LRP
Sphere Competition TC
Brushless AND Brushed
yes
Auto sensing
Automatic Brushless/Brushed
adaptation
yes
Type
forward/brake
Competition style
Case Size
-
Weight (excl. wires)
-
Voltage Input
4-6 cells (4.8-7.2 V)
Typical Voltage Drop (Brushless) @20A*
-
Rated Current (Brushless)*
-
Rec. Motor Limit (Bruhless)**
Over 3 turns
Typical Voltage Drop (Brushed) @20A*
-
Rec. Motor Limit (Brushed)**
Over 4 turns
Rated Current (Brushed)*
-
B.E.C.
5.5V, 3.0A
AutoCell System
NiMH-LiPo automatic adaption
yes
High Frequency
yes
Sensored Brushless System
yes
single sensor wire
Multi-Protection-System
yes
Modes, Speedo programms
for Brushless and Bruhsed
Advanced Digital with 4 Modes:
NiMH/LiPo,
ADPC Power Profiles,
Initial Brake,
Automatic Brake
Power Profiles - Brushless
ADPC
(Advanced Digital
Phase Control)
mit 6 Power Profiles
Power Profiles - Brushed
QC-3 Style
DEMS
(Digital Engine
Mapping System)
6 Power Profiles
Brake Profiles - Brushless
Inital Brake: 6 Level
Automatic Brake: 6 Level
Brake Profiles - Brushed
Inital Brake: 6 Level
Automatic Brake: 6 Level
LRP IceDrive Design
Yes
Connectors
12AWG power wires

 

Sphere Competition 2007  
Sphere
Brushless & Brushed Yes
Forward / brake Yes
Forward / brake / reverse Yes
Brushless system sensored
Protection system 3-way
Footprint (mm) 33.3 x 37.7
4 adjustable Modes

Mode 1: Brushed/Brushless and Forward/Brake/Reverse or Forward/Brake selection.

Mode 2: Punch Control, with three engine maps: Sportsman, for brushless operation limited to 24, 000 RPM, Low Grip, using LRP’s intelligent current limiting system, and Modified, for unlimited RPM and linear throttle operation.

Mode 3: Initial Brake with four levels:
 - Linear
 - Smooth
 - Medium
 - Aggressive.
Allows the driver to adjust the feel of his brakes.

Mode 4: Automatic Brake, adjustable in four levels:
 - No auto-brake
 - Smooth auto-braking
 - Medium auto-braking
 - Aggressive auto-braking.
This feature is especially important when using brushless motors, as it enables you to closely simulate the feel of driving a conventional brushed motor (with its inherent “drag” brake action) when coasting in neutral.

 

 
A.I. Brushless Pro Reverse digital
Motorlimit Brushless
over 8.5 Turns
Motorlimit Brushed over 7 Turns
Voltage input 4.8 - 9.6V
A.I. Brushless Reverse digital
Motorlimit Brushless
over 12.5 Turns
Motorlimit Brushed over 10 Turns
Voltage input 4.8 - 9.6V
NOSRAM
Matrix Evolution 2007 Edition New features comparing with Matrix Evolution:

- 8 maps instead of 6 for finer adjustments.
- latest team maps are incorporated for all classes.
- revised maps for new Storm Evolution 4.5t
- motor with sintered magnet.
- improved and more precise throttle control for all motors.

Matrix Evolution
Brushless & Brushed Yes, AUTOMATIC Adaptation
Forward / brake Yes
Forward / brake / reverse -
Typical voltage drop brushless* @20A* 0.018V
Rated current brushless* 400A / phase
Rec. motor limit brushless** Over 3.5 turns
Typical voltage drop brushed* @20A* 0.013V
Rated current brushed* 400A / phase
Rec. motor limit brushed** Over 5 turns
Brushless system sensored
Voltage input 4-7cells (4.8-8.4V)
4 adjustable Modes  - NiMH/LiPo
 - X.P.S.2 Power profiles
 - Iinitial brake
 - Automatic brake
Drive frequency high
B.E.C. 5.5V/3.0A
Protection system 3-way
Dimensions 33.1 x 37.6 x 14.9mm
Eeight (ecl. wires) 24.5g
Connectors 13awg power wires
*Transistors rating at 25°C junction temperature. Specifications subject to change without notice. **@6cell (7.2V)
 

Matrix
Brushless & Brushed Yes
Forward / brake Yes
Forward / brake / reverse Yes
Typical voltage drop brushless* @20A* 0.035V
Rated current brushless* 200A / phase
Rec. motor limit brushless** Over 5.5 turns
Typical voltage drop brushed* @20A* 0.026V
Rated current brushed* 200A / phase
Rec. motor limit brushed** Over 7 turns
Brushless system sensored
Voltage input 4-7cells (4.8-8.4V)
4 adjustable Modes

 - Brushless/brushed
 - Punch control
 - Initial brake
 - Automatic brake

Drive frequency high
B.E.C. 5.5V
Protection system 3-way
Dimensions 33.1 x 37.6 x 14.9mm
Eeight (ecl. wires) 24.5g
Connector

Standard tamiya style /13awg power wire set

*Transistors rating at 25°C junction temperature. Specifications subject to change without notice. **@6cell (7.2V)
 

TEAM NOVAK
XBR Sport ESC Features
 - Three user-selectable brushless throttle profiles including 2 with reverse
 - One brush racing throttle profile that surpasses GTX performance
 - 4 Adjustable Parameters within each profile: Minimum Brake, Drag Brake, Dead Band, and Minimum Drive
 - Compatible with sensored brushless and brushed motors
 - Built-in Li-Poly Cutoff Protection (can be activated in any of the 4 throttle profiles)
 - Auto-Detect Brushed Motor Mode (New Novak Feature!)
 - Built-in Motor Rotation Selector (New Novak Feature!)
 - User-friendly programming interface with 4 status LEDs
 - Novak’s One-Touch Set-Up (still the easiest)
 - Gold-Plated PCB Direct-Solder Wiring Tabs
 - User-replaceable input harness
 - Locked Rotor Detection Circuitry
 - Water-resistant case
 - Smart-Braking II so that user can “shift” from forward to reverse
 - Built-in power output for optional 6 volt accessory fan (Novak #5648 or #5646)
 - Thermal Overload Protection
 - Factory-installed power capacitor

 Specifications
 - Forward/Reverse Forward, Brake, Reverse (brushless mode); Forward, Brake (brush mode)
 - Input Voltage 4-7 Ni-Cd/Ni-MH cells (1.2V/cell) or 2 Li-Poly cells
 - On-Resistance 0.0012 ohms* (brushless: FWD/BRK/REV); 0.00027 ohms* (brush: FWD/BRK)
 - Footprint 1.54” x 1.18” (39 x 30 mm)
 - Weight 2.84 oz. (80.7 g) w/wires; 1.49 oz. (42.2 g) w/o wires
 - Rated & Braking Current 120 amps per phase*
 - Power Wires 14-Gauge
 - BEC 6.0 volt/1.5 amp
 - Motor Limit 8.5-turn brushless (at 6 cells Ni-MH); None (brushed)
 - Discrete Steps 512 Forward; 512 Reverse
 - Battery Plug Tamiya
 - Motor Plug None
 - Voltage Cut-off 6.25 volts (when Li-Poly Cutoff Circuitry is enabled)

GTB 4Cell
Input Voltage  4 Ni-Cd/Ni-MH cells (1.2V/cell)
Footprint ("/mm) 1.16 x 1.49 / 29.5 x 37.8
Height ("/mm) 0.61 /15.5
Weight (oz/g) 1.01 / 28.5
Motor Limit Any Novak 540-size brushless motor; No brushed motor limit
On-Resistance:  0.00040 ohms (brushless)*, 0.00013 ohms (brushed)*
Rated Current:  540 amps per phase (brushless)*, 1620 amps (brushed)*
Braking Current: 540 amps per phase (brushless)*, 1620 amps (brushed)*
BEC: 6.0 volt/3.0 amp
Discrete Steps: 1024 Forward
1024 Reverse 

Power Wires: 16-Gauge 
Battery Plug: None
Motor Plug: None
Status LEDs: 4

 - Includes six throttle profiles specifically designed for 4-cell racing
 - 25% lighter and 30% smaller height profile than the #1710 GTB ESC
 - User-friendly programming interface with 4 status LEDs
 - Novak’s One-Touch Set-Up (still the easiest)
 - Gold-Plated PCB Direct-Solder Wiring Tabs
 - Re-solderable user-replaceable input harness
 - Re-solderable user-replaceable switch harness
 - Thermal Overload Protection
 - Water-resistant case
 - Radio-Priority Circuitry
 - Radio-Priority Circuitry
 - Polar Drive Circuitry
 - Designed and Manufactured in the USA
 - 4 Adjustable Parameters (5 in Brushed Mode):
* Minimum Brake
* Drag Brake
* Dead Band
* Minimum Drive
* Drive Frequency (In Brushed Mode Only)

GTB
Input Voltage  4-6 cells (1.2V/cell)
Footprint ("/mm) 1.16 x 1.49 / 29.5 x 37.8
Weight  1.36 / 38.5
Motor Limit None (Compatible with all Novak 540-size brushless motors)
On-Resistance:  0.00040 ohms (per each phase -3) 0.00013 ohms (brushed mode)
Throttle Profiles: 5 brushless (2w/rev), 1 brushed
brushless programmable   5 throttle profiles
(3 forward/brake; 2 w/reverse)
BEC: Heavy-duty 6V/3A
4 Adjustable Parameters in all profiles Minimum Brake
Drag Brake
Deadband
Minimum Drive
Fully programmable racing brushed mode including adjustable Drive Frequency
User-friendly programming interface with 4 different color status LEDs
Gold-Plated PCB Direct-Solder Wiring Tabs
User-replaceable input harness and switch harness
Thermal Overload Protection
Radio-Priority Circuitry
Polar Drive Circuitry
Clear cooling fan (30x30x8mm) mounted on factory-installed heat sink
Factory-installed power capacitor module
Water-resistant case

 

 

Crawler System

Input Voltage  4-6 cells (1.2V/cell)
Footprint ("/mm) 1.32x1.75 / 33.5x44.5
Weight (oz/grs)  1.7 / 48.2 (wo power wires
On-Resistance:  0.0019 ohms (per each phase -3)
BEC: Heavy-duty 6V/3A
4 Adjustable Parameters in all profiles Minimum Brake
Drag Brake
Deadband
Minimum Drive
2 Driving Profiles:
Profile 1: Normal motor rotation;
Profile 2: Reverse motor rotation
Expanded drag brake values for improved holding power during maneuvering
Small Dead Band (3%) for finer throttle control
Fits in popular 1/10 scale electric R/C cars
Variable Throttle Step
One-Touch Set-Up
Transmitter Check Mode
Locked Rotor Detection Circuitry
Direct-solder wiring tabs for flexible soldering options
User-replaceable input harness
Thermal Overload Protection
Quark

Plasma

Specs
Input Voltage: Ni-Cd 4-18 cells, Lithium 1-6 cells
Continuous: 100A (@Full throttle, 25°C)
Resistance: Brushless mode - 0.00045Ω (per each phase, .00135Ω total)
Brushed mode - 0.00015Ω
Motor Limit: No limit (540 Sized Motors)
BEC: 5.5V/3A with 6 cell Ni-Cd input
5.5V/3A with 18 cell Ni-Cd input
Footprint: 45mm X 30mm
Weight: 58 grams (w/o wires)

Features
- Fully Compatible with Brushed and Brushless motors, both sensor and sensorless.
- Extremely wide Battery voltage range (Ni-Cd/Ni-MH: 4-18 cell, Lithium: 1-6 cell)
- Includes Man Machine Interface (MMI) Program Box, for Programming with ease, no PC required.
- New traction control feature puts the ideal amount of power to the drive wheels to not breaking traction for superior acceleration on any surface.
- Quark Plasma offer 4 types of braking setups including the new Velocity Responsive Braking System, which adjusts braking strength proportionally to the speed on the vehicle.
- More than 32 steps for Adjustable Current limiter, Acceleration Traction Control, Braking.
- 3 Advanced Braking Modes:
- Fixed Type (Proportional ABS)
- Automatic (Full automatic under velocity)
- Auto + Fix (Automatic with proportional ABS)
- New advanced FAIL SAFE function. Plasma recognizes master transmitter signal, so interference will not affect the Plasma (Standard Fail Safe also included).
- Multiple built in Protections include Temperature, Voltage Cut-off, and Fail Safe. Users will also be able to keep tabs on operating temperatures as the Plasma stores the highest temp., which can be retrieved easily using the MMI.
- Updated brushless drive profiles for smooth acceleration and NO COGGING! This software also runs sensor type motors without the need for sensor wires.
- Extremely low noise (-105dBm), and 95% efficiency Switching type BEC can supply 5.5V/3A continuous every with very high Input voltages (Up to 30V).
- World’s lowest noise generation helps signal strength even with long distances and noisy areas.

On the following page, brushless motors are shown.