KAVAN Pro ESCs - Instruction manual

Introduction

Programmable Electronic Controllers for Brushless Motors

Congratulations on your purchase of a KAVAN Plus line electronic speed controller for brushless motors. The state-of-the-art KAVAN PRO line covers almost the entire range of electric-powered planes and helicopters - from small and light models, up to giant ones. Large gliders equipped with several servos or 3D models with strong digital servos will benefit from the powerful switched SBEC voltage stabiliser of KAVAN Pro controllers. KAVAN PRO OPTO HV controllers are here for your 6-14S LiPo power systems. All the ESCs can be quickly programmed using your transmitter and even easier with the optional Program card KAVAN PRO.

Warnings

• Read through the manuals of all power devices and aircraft and ensure the power configuration is rational before using this unit.
• Ensure all wires and connections are well insulated before connecting the ESC to related devices, as a short circuit will damage your ESC. Ensure all devices are well connected, to prevent poor connections that may cause your aircraft to lose control or other unpredictable issues like damage to the device. If necessary, please use a soldering iron with enough power to solder all input/ output wires and connectors.
• Never get the motor locked up during high-speed rotation, otherwise, the ESC may get destroyed and may also get your motor damaged. (Note: move the throttle stick to the bottom position or disconnect the battery immediately if the motor really gets locked up.)
• Never use this unit in extremely hot weather or continue to use it when it gets overheated. High temperature will activate the ESC thermal protection or even damage your ESC.
• Always disconnect and remove batteries after use, as the ESC will continue to consume current as long as it's connected to the batteries. Long-time contact will cause batteries to completely discharge and damage batteries and/or ESC. This will not be covered under warranty.
• When used in EDF aeroplanes, the "Normal Start-up" mode is not viable due to the characteristics of the ducted fan & motor. If the diameter of the ducted fan is 75 mm to 90 mm (90 mm is not included), please select the “Soft Start-up” or "Very Soft" start-up mode. If the diameter of the ducted fan is 90 mm or above, please select the "Very Soft" start-up mode.

Features

• ESC, which features a high-performance 32-bit ARM M4 microprocessor (with a running frequency of up to 72 MHz), is compatible with various brushless motors.
• A microprocessor powered by a separate DC controller has better anti-interference performance, greatly reducing the possibility of losing control.
• DEO (Driving Efficiency Optimization) Technology greatly improves throttle response & controlling efficiency and reduces ESC's temperature.
• Built-in high-power BEC with output voltage adjustable among 5.2 V, 6.0 V and 7.4 V (5.2 V PRO R-20SB/R-30SB). The BEC module is separated from other circuits on the ESC, so the normal BEC output can be guaranteed (when an issue like a burnt power board occurs) to allow users to get the aircraft back before crashing.
• Normal/Soft/Very Soft start-up modes are compatible with regular propeller aeroplanes and EDF jet aeroplanes (please make sure to select the “Very Soft Start-up” mode when using EDF jet aeroplanes).
• A separate programming cable for connecting the ESC to an LED program card allows users to program the ESC anytime, anywhere. (For detailed info, please refer to the user manual of the KAVAN PRO LED programming card.)
• Normal/proportional/reverse brake modes (especially reverse brake mode) can effectively shorten the landing distance of the aircraft.
• Multiple protection features like start-up, ESC thermal, capacitor thermal, over-current, over-load, abnormal input voltage and throttle signal loss effectively prolong the service life of the ESC.

Specification

	Cont. current	Peak current	Input voltage	BEC output	Weight	Dimensions
KAVAN PRO G2 R-20SB	20 A	30 A	2–4S LiPo	5.2 V, 2.5 A continuous / 4 A peak	13 g	25×15×5 mm
KAVAN PRO G2 R-30SB	30 A	45 A	2–4S LiPo	5.2 V, 3.5 A continuous / 5 A peak	23 g	37×17×5 mm
KAVAN PRO G2 R-40SB	40 A	60 A	3–6S LiPo	5.2, 6.0, 7.4 V, 8 A continuous / 20 A peak	44 g	47×28×14 mm
KAVAN PRO G2 R-60SB	60 A	80 A	3–6S LiPo	5.2, 6.0, 7.4 V, 8 A continuous / 20 A peak	73 g	69×35×18 mm
KAVAN PRO G2 R-80SB	80 A	100 A	3–8S LiPo	5.2, 6.0, 7.4 V, 8 A continuous / 20 A peak	92 g	70×35×19 mm
KAVAN PRO G2 R-120SB	120 A	150 A	3–8S LiPo	5.2, 6.0, 7.4 V, 8 A continuous / 20 A peak	93 g	77×35×19 mm
KAVAN PRO G2 R-130HV OPTO	130 A	160 A	6–14S LiPo	None	221 g	110×50×33 mm
KAVAN PRO G2 R-160HV OPTO	160 A	200 A	6–14S LiPo	None	221 g	110×50×33 mm

Connecting the ESC

The speed controller can be connected to the motor by soldering directly or with high-quality connectors. Always use new connectors, which should be soldered carefully to the cables and insulated with a heat shrink tube. Use only high-quality connectors to connect the ESC to the flight pack as well.

Caution: Please bear in mind improper polarity or short circuit will damage the ESC, therefore, it is your responsibility to double check all plugs for proper polarity, and proper connection BEFORE connecting the battery pack for the first time, (+) RED, (- BLACK).

1. Throttle Signal cable (long White/Red/Black tri-colour cable or 2-wire White/Black with R-130 and R-160 HV OPTO): plug it into the TH channel on the receiver or flight controller. The White wire is for transmitting the throttle signals, the Red & Black wires are BEC output wires.
2. Reverse Brake Signal wire (Yellow wire): it must be plugged into any vacant channel on the receiver (when using the Reverse Brake mode) to control the ON/OFF of the Reverse Brake function.
3. Programming cable (short White/Red/Black Tri-colour cable): connect it to an LED program box if users want to program the ESC.

Note:

1. PRO 130HV OPTO and 160HV OPTO don't have the Reverse Brake Signal wire.
2. PRO 130HV OPTO and 160HV OPTO don't have the BEC output wire (long red wire).
3. PRO R-20SB and R-30SB – the Yellow wire is the programming cable.

Powering up the KAVAN Pro ESC for the first time, Throttle calibration

ESC/Radio Calibration

Caution: The default throttle range of this ESC is 1100–1940 μs (Futaba standard); users need to calibrate the throttle range when they start using a new KAVAN Pro brushless ESC or another transmitter.

The KAVAN PRO ESC features Automatic Throttle Calibration to ensure the smoothest throttle response and resolution throughout the entire throttle range of your transmitter. This step has to be performed just once to allow the ESC to "learn and memorise" the throttle output signal of your transmitter. It only needs to be repeated if you change your transmitter.

1. Turn on the transmitter and move the throttle stick to the top position.
2. Connect a battery to the ESC; the motor will emit "123" to indicate the ESC is normally powered on.
3. Then the motor will emit two short beeps to indicate the maximum throttle endpoint is accepted.
4. Move the throttle stick to the bottom position within 5 seconds after the two short beeps, the minimum throttle position will be accepted 1 second later.
5. The motor emits "Number" beeps to indicate the number of LiPo cells you plugged in.
6. The motor emits a long beep to indicate the calibration is complete.

Normal ESC start-up procedure

1. Turn on the transmitter, and then move the throttle stick to the bottom position.
2. After connecting the ESC to a battery, the motor will emit "123" to indicate the ESC is normally powered on.
3. The motor will emit several beeps to indicate the number of LiPo cells.
4. The motor emits a long beep to indicate the ESC is ready to go.

Programmable functions of the KAVAN Pro ESC

	Value	1	2	3	4	5	6	7	8
	Sound signal	B-	B- B-	B- B- B-	B- B- B- B-	B----	B---- B-	B---- B---- B-	B---- B- B- B-
1	Brake type	Disabled	Normal	Proportional	Reverse
2	Brake force	Disabled	Level 1	Level 2	Level 3	Level 4	Level 5	Level 6	Level 7
3	Voltage cut-off type	Soft	Hard
4	LiPo cells	Auto Calc.	3S	4S	5S	6S	8S		(SB)
			6S	8S	10S	12S	14S		(HV)
5	Cut-off voltage	Disabled	2.8 V	3.0 V	3.2 V	3.4 V	3.6 V	3.8 V
6	BEC voltage	5.2 V	6.0 V	7.4 V
7	Start-up mode	Normal	Soft	Very soft
8	Timing	0°	5°	8°	12°	15°	20°	25°	30°
9	Motor direction	CW	CCW
10	Freewheeling	Enabled	Disabled

*) Factory default setting varies depending on the ESC type.

Brake Type

• Normal Brake: After selecting this option, the brake function will be activated when you move the throttle stick to the bottom position. In this mode, the brake amount equals to the brake force you’ve preset.
• Proportional Brake: After selecting this option, the throttle range of 20–100 % (on the transmitter) will correspond to the ESC throttle output of 0–100 % while the throttle range of 20–0 % (on the transmitter) will correspond to the brake force of 0–100 %.

Note: KAVAN PRO R-20SB and R-30SB don’t have this function.

• Reverse Brake: After selecting this option, the Reverse Brake signal wire (its signal range must be the same as the throttle range) must be plugged into any vacant channel on the receiver, and you can control the motor direction via that channel. The channel range of 0–50 % is the default motor direction, the channel range of 50–100 % will cause the motor to spin counterclockwise. The channel stick should be within the channel range of 0–50 % (0 would be better) when the first time you power on the ESC. After the Reverse function is activated, the motor will stop first and then spin in the reversed direction and then increase to the speed corresponding to the throttle input. Either signal loss, no matter whether reverse brake signal loss or throttle signal loss during the flight can cause the throttle signal loss protection to be activated.

Note: KAVAN PRO R-20SB/R-30SB/R-130HV/R160HV OPTO don't have this function.

Brake Force

This item is adjustable from level 1 to level 7. The higher the level, the stronger the braking effect. It’s only effective in the "Normal brake" mode.

Voltage Cut-off Type

Soft Cut-off: After selecting this option, the ESC will gradually reduce the output to 50 % of the full power in 3 seconds after the low-voltage cut-off protection is activated. Hard Cut-off: After selecting this option, the ESC will immediately cut off the output when the low-voltage cut-off protection is activated.

LiPo Cells

The ESC will automatically calculate the number of LiPo cells you have plugged in as per the "3.7V/Cell" rule if "Auto Calc." is selected, or you can set this item manually (recommended).

Cutoff Voltage

This item is adjustable between 2.8–3.8 V (they are the cutoff voltages for one cell), it’s 3.0 V by default, or you can disable it if necessary.

BEC Voltage

This item is adjustable between 5.2 V, 6.0 V and 7.4 V.

Note: KAVAN PRO R-20SB/R-30SB/R-130HV/R160HV OPTO don’t have this function.

Start-up Mode

• Normal Start-up: After selecting this option, the motor will immediately start spinning and then quickly reach the corresponding speed when you move the throttle stick from the bottom position to the top position.
• Soft Start-up: After selecting this option, the motor will slowly start spinning and then quickly reach the corresponding speed when you move the throttle stick from the bottom position to the top position.
• Very Soft Start-up: After selecting this option, the motor will slowly (slower than in "Soft Start-up Mode") start spinning and then quickly reach the corresponding speed when you move the throttle stick from the bottom position to the top position.

We recommend selecting the "Soft Start-up" or "Very Soft Start-up" mode when you are flying an aeroplane with a big-sized ducted fan. Please ensure to select the “Very Soft Start-up” mode if the diameter of the ducted fan on your airplane is over 90 mm.

Timing

This item is adjustable between 0–30 degrees.

Motor Rotation

This item allows you to adjust the rotation direction of your motor between CW and CCW.

Freewheeling

This item is adjustable between "Enabled" and "Disabled", and it is enabled by default. With it enabled, you can have better throttle linearity or smoother throttle response.

Programming the KAVAN PRO ESC

There are two ways to program the ESC. One way is to program it with the optional | KAVAN Pro Programming Card and the other way is to program it with the transmitter. The ESC has many programmable items, so we recommend using the programming card to do so.

Using the KAVAN PRO programming card (optional)

• Plug the short programming cable (on your ESC) into the programming port on the | KAVAN Pro Programming Card.
• (With a battery connected to your ESC), after connecting the KAVAN PRO Programming card to the ESC, you need to disconnect the battery first and then reconnect it to the ESC to enter the programming mode to check and set parameters.
• The portable KAVAN PRO Programming card is an optional accessory applicable for field use. Its friendly interface makes ESC programming easy and quick.
• Connect a battery to your ESC after connecting the KAVAN PRO Programming card to the ESC, all programmable items will show up a few seconds later. You can select the item you want to program and the setting you want to choose via the "ITEM" and "VALUE" buttons on the program box, and then press the "OK" button to save all new settings to your ESC.

Visit KAVAN Pro programming card - Instruction manual for a detailed info about your programming card.

Note: KAVAN PRO R-20SB/R-30SB – Plug the throttle signal cable into the power port of the LED programming card and the programming cable (yellow wire) into the programming port on the LED programming card.

Attention: You need to power your ESC off and then on after adjusting the parameters. Otherwise, new parameters won't take effect.

Programming the KAVAN Pro ESC with a transmitter

Entering the programming mode

Note: Please make sure the throttle channel EPA is set to -100 % when the throttle stick is at the bottom position and +100 % for the top position (or the throttle curve 0–100 %).

Enter program mode

Turn on the transmitter, move the throttle stick to the top position, and connect a battery to the ESC, 2 seconds later, the motor will beep ”B-B-” first, then emit "♪ 56712" 5 seconds later to indicate that you are in the ESC programming mode.

Select programmable items

After entering the programming, you’ll hear the following 12 kinds of beeps circularly. Move the throttle stick to the bottom position within 3 seconds after you hear some kind of beeps, you’ll enter the corresponding parameter item.

1. "B-" Brake Type (1 short beep)
2. "B- B-" Brake Force (2 short beeps)
3. "B- B- B-" Voltage Cutoff Type (3 short beeps)
4. "B- B- B- B-" LiPo Cells (4 short beeps)
5. "B——" Cutoff Voltage (1 long beep)
6. "B—— B-" BEC Voltage (1 long beep and 1 short beep)
7. "B—— B- B-" Start-up Mode (1 long beep and 2 short beeps)
8. "B—— B- B- B-" Timing (1 long beep and 3 short beeps)
9. "B—— B- B- B- B-" Motor Direction (1 long beep and 4 short beeps)
10. "B—— B——" Freewheeling (2 long beeps)
11. "B—— B—— B-" Factory Reset (2 long beeps and 1 short beep)
12. "B—— B—— B- B-" Exit (2 long beeps & 2 short beeps)

Note: A long "B——" equals to 5 short "B-", so a long "B——" and a short "B-" represents the 6th item in "Select Parameter Items".

Set item value (Programmable value)

The motor will beep different kinds of beeps circularly, move the throttle stick to the top position after you hear some kind of beeps will get you to the corresponding parameter value, then you’ll hear the motor emit "♪ 1515" to indicate the value is saved, then get back to "Select Parameter Items" and continue to select other parameter items that you want to adjust.

Exit program mode

Move the throttle stick to the bottom position within 3 seconds after you hear two long beeps and two short beeps (emitting from the motor) to exit the programming mode. The motor beeps "Number" beeps to indicate the number of LiPo cells you have plugged in, and then a long beep to indicate the power system is ready to go.

Protection functions

Start-up Protection

The ESC will monitor the motor speed during the start-up process. When the speed stops increasing or the speed increase is not stable, the ESC will take it as a start-up failure. At that time, if the throttle amount is less than 15 %, the ESC will try to restart automatically; if it is larger than 20 %, you need to move the throttle stick back to the bottom position first and then restart the ESC. (Possible causes of this problem: poor connection/ disconnection between the ESC and motor wires, propellers are blocked, etc.)

ESC Thermal Protection

The motor will "stutter" when the ESC temperature goes above 110 °C to indicate that the ESC thermal protection is activated. If you lower down the throttle input to below 60 % at this moment, the "stuttering" will disappear and the ESC will output the corresponding power. The motor will re-start to "stutter" if the throttle input exceeds 60 %. In this condition, disconnect the battery first and then re-connect it to the ESC after the ESC cools down (the ESC temperature cannot exceed 70 °C, otherwise it cannot be started), it will resume normal operation.

Throttle Signal Loss Protection

When the ESC detects loss of signal for over 0.25 seconds, it will cut off the output immediately to avoid an even greater loss, which may be caused by the continuous high-speed rotation of propellers or rotor blades. The ESC will resume the corresponding output after normal signals are received.

Overload Protection

The ESC will cut off the power/output or automatically restart itself when the load suddenly increases to a very high value. Possible cause of the sudden load increase is that the propellers are blocked or the motor and the ESC are out of sync.

Over-current Protection

The ESC will cut off the output immediately when the peak current exceeds the regulated value and then restart to resume the output. If the current continues to go above the regulated value, then the output will be completely cut off. This protection may be activated by the burnt motor or some other causes.

Safety precautions

• Do not install the propeller (fixed wing) or drive pinion (helicopter) on the motor when you test the ESC and motor for the first time to verify the correct settings on your radio. Only install your propeller (plane) or pinion (heli) after confirming the settings on your radio are correct.
• Never use ruptured or punctured battery cells.
• Never use battery packs that are known to overheat.
• Never short circuit battery or motor terminals.
• Always use proper insulation material for cable insulation.
• Always use proper cable connectors.
• Do not exceed the number of cells or servos specified for the ESC.
• Wrong battery polarity will damage the ESC and void the warranty.
• Install the ESC in a suitable location with adequate ventilation for cooling.
• Use only batteries supported by the ESC and ensure the correct polarity before connecting.
• Switch your transmitter ON first and ensure the throttle stick is in the minimum position before connecting the battery pack.
• Never switch your transmitter OFF while the battery is connected to your ESC.
• Only connect your battery pack just before flying and do not leave your battery pack connected after flying.
• Handle your model with extreme care once the battery pack is connected and keep away from the propeller at all times. Never stand in line or directly in front of any rotating parts.
• Do not immerse the ESC under water, do not allow it to get wet while powered up.
• Always fly at a designated flying site and follow the rules and guidelines set by your modeller’s club.

Recycling and waste disposal note (European Union)

Electrical equipment marked with the crossed-out waste bin symbol must not be discarded in the domestic waste; it should be disposed of via the appropriate specialised disposal system. In the countries of the EU (European Union) electrical devices must not be discarded via the normal domestic waste system (WEEE - Waste of Electrical and Electronic Equipment, Directive 2012/19/EU). You can take your unwanted equipment to your nearest public collection point or recycling centre, where it will be disposed of in the proper manner at no charge to you. By disposing of your old equipment in a responsible manner you make an important contribution to the safeguarding of the environment.

EU declaration of conformity (European Union)

Hereby, KAVAN Europe s.r.o. declares that these KAVAN Pro line brushless electronic speed controllers are in compliance with the essential requirements as laid down in the EU directive(s) concerning electromagnetic compatibility. The full text of the EU Declaration of Conformity is available at http://www.kavanrc.com/doc.

Guarantee

The KAVAN Europe s.r.o. products are covered by a guarantee that fulfils the currently valid legal requirements in your country. If you wish to make a claim under guarantee, please contact the retailer from whom you first purchased the equipment. The guarantee does not cover faults which were caused in the following ways: crashes, improper use, incorrect connection, reversed polarity, maintenance work carried out late, incorrectly or not at all, or by unauthorised personnel, use of other than genuine KAVAN Europe s.r.o. accessories, modifications or repairs which were not carried out by KAVAN Europe s.r.o. or an authorised KAVAN Europe s.r.o., accidental or deliberate damage, defects caused by normal wear and tear, operation outside the Specification, or in conjunction with equipment made by other manufacturers. Please be sure to read the appropriate information sheets in the product documentation.