KAVAN Smart PRO Opto ESCs - Instruction manual

Introduction

Smart Programmable Electronic Controllers for Brushless Motors

Congratulations on your purchase of a KAVAN Smart PRO line electronic speed controller for brushless motors. The KAVAN Smart PRO product line represents advanced brushless motor controllers for use exclusively in RC model aircraft. With integrated telemetry and various user configuration options, the controllers offer high efficiency, low weight and precise motor control. All the ESCs can be quickly programmed using your transmitter, PC or an external terminal.

Features

• Small size combined with high power for motor control.
• Over-voltage and under-voltage protection, over-temperature protection, motor sudden stop protection.
• Adjustable current limiter.
• Fast and accurate Heli/governor mode with many settings.
• Optically isolated gas inlet.
• Safety shutdown of the engine when the throttle pulse is lost.
• Configurable acceleration, timing, electromagnetic brake, motor reversal, etc.
• Low acoustic noise due to high frequency switching.
• Automatic telemetry: Fport, can be set via Lua script. Alternative firmware Duplex EX, Hott, MSB, PowerBox P2Bus, S.Bus2, Spectrum SRXL2.
• Telemetry (depending on the RC system): voltage, current, power, capacitance, temperature, speed, energy.
• Zaznamenávají se minimální/maximální hodnoty telemetrie.
• Configuration via transmitter, PC software MAV Manager or external terminal (JETIBOX/SMART-BOX).
• Firmware update via USB interface.
• Languages: CZ/DE/EN/FR/IT.

	IBEX-80	BEX-120	IBEX-130	IBEX-200	IBEX-220
Dimensions	57×35×28 mm	58×53×24 mm	58×53×28 mm	81×63×35 mm	81×63×35 mm
Weight incl. cables	60 g	110 g	110 g	270 g	270 g
Continuous current	80A	120A	130A	200A	220A
Peak current	120A/2s	160A/2s	180A/2s	260A	280A
Supply voltage	8–51V	10–59V (max. 64V)	10–51V	12–59V (max. 64V)	10–51V
LiPo articles	3–12	4–14	4–12	4–14	4–12
LiFe articles	3–14	4–16	4–14	4–16	4–14
Battery/motor cables	4 mm²/2.5 mm²	4 mm²/4 mm²	4 mm²/4 mm²	6 mm²/6 mm²	6 mm²/6 mm²
Circuit antispark	No	Yes	Yes	Yes	Yes
Recommended connectors	G4 (75A) XT90 (90A)	G5.5 (150A)	G5.5 (150A)	G8 (170A)	G8 (170A)
Temperature range	-10÷110°C
PWM frequency	20kHz
Operating current	50mA			60mA
Standby current	4mA			10mA
Propeller positioning	With additional Hall sensor
Telemetry	Duplex EX, Multiplex MSB, Futaba S.Bus2, Graupner Hott, PowerBox P2Bus, Spectrum SRXL2™
Status LED	Yes
Active brake (freewheeling)	Yes
BEC	No
Optical isolation	Gas input only			Complete
Maximum speed	> 300 000 eRPM (two-pole motor)

Installation

Fix the controller in your model with the screws. Alternatively, you can use Velcro or double-sided tape to secure it. Connect the motor and receiver according to the diagram below. You can connect the motor cables in any order you like, as changing the direction of rotation is done by swapping either of the two cables (alternatively also by the "Direction" parameter in the configuration). Switch on the transmitter and then the receiver - the latter uses a separate battery. Now you can plug in the main flight battery.

Controller mode

It is possible to select from three basic controller modes:

• Normal - the preset acceleration curve is always used when accelerating. This is the default mode for normal use.
• Fast mode - the selected acceleration time is only applied when spinning from zero speed. Then the minimum possible delay (0.2s for zero to full throttle response) is applied.
• Normal with reversal - behaves similarly to normal mode. In addition, you can select a throttle reversal channel that will control the direction of the engine speed during flight.
• Heli/Governor - fast and precise constant speed control with many adjustable parameters.

Gas input signal

The controller expects positive pulses from the receiver with a maximum refresh rate of up to 400Hz. By default, when the endpoints are set automatically, the controller will work with the vast majority of RC systems. In this case, a minimum throttle signal pulse is loaded upon startup. The maximum output is then dynamically adjusted when you first give full throttle.

In case you need the exact positions of the transmitter lever, where the engine starts and where the throttle is full, you can configure using manually entered endpoints.

Engine settings

Many motor parameters can be configured including acceleration, timing, gear ratio or number of poles. The gear ratio and pole count are important for telemetry and correct display of motor speed.

Acceleration affects the engine's response to the throttle channel. Reducing the acceleration time will speed up the engine response and give the pilot a sense of instant control during aerobatics. However, the engine consumes more power and the controller generates more heat. For most types of models, including electric gliders, layouts, EDFs, etc., we recommend a default acceleration of 1.0s. For 3D aerobatic flight you can go down to 0.5s or even less (with caution). You can also set the controller's "Fast Mode" in the General Settings menu for the fastest possible motor response.

Timing is determined by the type of engine and is usually recommended by the engine manufacturer. Timing also affects power and current consumption. A higher timing value can increase motor performance, but care must be taken to avoid overloading the system.

• Automatic timing: timing is continuously adjusted by an internal algorithm. It is a universal solution compatible with most motor types.
• Timing 0° - 10°: Recommended for inrunners, i.e. motors with internal magnets.
• 15° - 20° timing: Recommended for most outrunners (rotary jacket motors). Offers a good combination of performance and efficiency.
• 25° - 30° timing: High torque motors with many poles require the highest timing.

The motor type should only be changed in some specific cases where the application requires it.

There are three options:

• "Standard" motor type - recommended for most types and applications (default).
• "High Torque" - if you have problems with engine synchronisation during rapid acceleration, use this mode. Prerequisites: large engine with rotating casing and more than 20 poles, heavy propeller, large current peaks. We also recommend increasing the timing to more than 20°.
• "High speed" - use this mode if your drive exceeds 250,000 eRPM (RPM calculated for a 2-pole motor).

Starting power is affected by the first few revolutions of the engine. If you are not satisfied with the automatic mode, you can set the engine to run more aggressively (positive values) or as smoothly as possible (negative values).

Brake setting

The electromagnetic brake is a standard feature of all controllers used in electric glider models. KAVAN SMART PRO controllers offer several additional parameters for fine tuning the brake function. You can use one of the pre-configured settings or you can freely adjust all brake parameters.

Setting options:

Off: The propeller rotates freely without braking.

Soft: Transition from zero to full braking force in 1.0s.

Medium: Transition to full braking force in 0.7s.

Hard: Transition from 50% to 100% braking force in 0.5s.

Manual: You can enter all brake parameters manually:

• Initial force (start of brake) - braking force applied from the moment the brake is applied.
• End force (end of brake) - the braking force applied after the start-up time has elapsed (usually the full braking force that brings the engine to a complete stop).
• Brake ramp - the time between the start and end of the brake. During this time, the braking force changes continuously from initial to final power.
• Waiting time - the time between disconnecting the engine and applying the brake. During this time, the motor rotates freely without power.

Example: motor brake with the following parameters: brake start = 50%, brake end = 100%, ramp = 0.5s, wait time = 0.3s.

Propeller positioning

The positioning function allows the engine/propeller to be rotated to the exact position required for a safe landing, or is just convenient for the next flight. With a few external components (Hall sensor and small magnet) you can use this function and avoid the risk of damaging the propeller during landing. The magnet must be properly attached to the rotating part (engine or propeller) and the Hall sensor must be positioned in the fuselage so that the magnet is opposite the Hall sensor at the target position of the propeller. After enabling the positioning function via the controller menu (Propeller Position = "Hall Sensor"), also set the PWM positioning so that the motor spins slowly but smoothly. You can also change the duration of the actively held motor position (Position Hold), which is activated when the correct position is found. The Hold Position feature is useful in a retractable drive because it prevents the propeller from moving spontaneously during retraction.

To enable propeller positioning, connect the Hall sensor to the IN-B port on the controller.

Engine identification

Some brands of motors include an integrated temperature sensor compatible with KAVAN SMART PRO controllers. This sensor (T125-ID) can also be used as a stand-alone telemetry sensor with Duplex/Hott/S.Bus2/Fport telemetry support. In addition, it can be connected directly to the "IN-A" input port on the controller (see picture above). From this point on, the KAVAN SMART PRO controller will know the basic motor parameters (minimum acceleration, recommended timing, gear ratio, number of poles...) and also the current motor temperature. Some parameters will be reset automatically (gear ratio, number of poles), other setting items will be applied once you reset the controller to factory settings. The motor identification sensor is connected to the IN-A port on the controller.

Synchronous switching

"Synchronous switching" or "Active braking" is a function of the speed controller that reduces the heat generated by it during part-load operation. This mode is useful for aerobatic pilots who want not only fast acceleration but also fast deceleration. The engine instantly follows the throttle movement in both directions and the pilot is able to take control perfectly.

Current limiter

The current limiter is part of the safety features of the controller. It does not stop the motor at overcurrent, but constantly monitors the instantaneous current consumption and adjusts the motor output based on it. When this function is enabled, specify the maximum current allowed and the controller will immediately reduce motor power when the current threshold is exceeded. After the current returns to a safe level, motor power is restored.

Battery protection

Integrated battery protection is based on undervoltage detection and motor power reduction or complete shutdown. You can freely set the number of cells (or leave the automatic detection) and the value of the minimum voltage per cell. The supported battery types are NiXX (1.2 V), LiFe (max. 3.6 V) and LiIo/LiPo (max. 4.2 V).

Antispark function

The KAVAN SMART PRO 120/130 and KAVAN SMART PRO 200/220 controllers contain an additional circuit that can optionally be used to prevent sparks when connecting the drive battery. This circuit is connected to the drive kit using a separate cable. Use the "Antispark" cable only for precharging the controller capacitors. Never use this cable to power the motor or any external electronic components.

Status codes

Status codes are displayed on the screen (JETIBOX/SMART-BOX) if any error event occurs. If any status code is activated, the red LED flashes continuously.

Available status codes:

• Low Voltage (UL): the battery voltage has fallen below the threshold level specified in the Battery Protection menu and the controller has either reduced the maximum power or shut down the motor completely.
• High voltage (UH): If you are using a soft battery or mains power supply, the voltage may rise above the initial level during braking. In this case, an alarm is triggered and all braking functions are disabled.
• High current (IH): the current is higher than the maximum peak current defined in the product specification (e.g. 120A for KAVAN SMART PRO 80, 200A for KAVAN SMART PRO 130).
• High temperature (T100, T110, T120): the temperature is above a safe level. The numeric value indicates the maximum temperature detected and the safety protocol that has been activated.
• Commutation (COM) error: a synchronization error was detected while the motor was running. This usually occurs when the engine stops suddenly or in the case of very fast acceleration on some specific power units. This error may indicate a serious problem in the motor-controller installation.

Režim Heli/governor

The speed controllers include a fast and accurate speed stabilization function.  You can configure the governor mode in many ways to suit your preferences.

Make sure the propeller blades are removed before activating the constant speed mode. In the General Settings menu, select the controller mode to "Heli/Governor" and follow the options below:

• Set the minimum and maximum speed of the main rotor according to your preference. As soon as you move the throttle beyond the idle position, the engine will slowly spin up until it reaches the target speed. These are calculated by the throttle channel position, where throttle off corresponds to "Minimum RPM" and full throttle corresponds to "Maximum RPM".
• Set the Start Acceleration to make the engine start as smoothly as possible. You can set this time up to 60s. Start-up Acceleration is used when the engine is revving from zero speed or when the autorotation rapid exit function is deactivated.
• Configure the autorotation rescue time and autorotation acceleration. The autorotation rescue function is used when you need to end autorotation quickly and prevent the model from crashing. In this case, you move the throttle beyond the idle position, "Autorotation Acceleration" is used to spin the engine until it reaches the desired RPM. The "Autorotation Rescue" parameter determines the time after engine shutdown when the autorotation rescue function can be activated. When this time is exceeded, the standard start-up time is used.