KAVAN Smart PRO Opto ESCs - Instruction manual

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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.


	ESC-80	ESC-120	ESC-130	ESC-200	ESC-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.

Mode 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.
Advanced settings: governor gains - (P)roportional and (I)ntegral. You can adjust these gains to fine-tune the governor's response to rapid load changes during flight maneuvers. Please make the changes only in small increments and verify the resulting behavior in a short test flight.
Increase the gain P to remove small speed fluctuations during straight flight, e.g. hovering. If you hear unexpected motor/gearbox noise (indicating rapid oscillation), reduce P gain by 20%.
Increase gain I to maintain precise speed during manoeuvres. If the engine speed starts to fluctuate noticeably, reduce the I-gain by 20%.
In Governor mode, fixed throttle channel endpoints are always used (standard 1.1ms - 1.9ms) and active braking is also enabled.

Reversing the direction of rotation

The reverse motor function is available for RC systems with bidirectional bus support (EX Bus, P 2Bus, SRXL2, S.Bus2, Fport). To control the direction of the motor, you must define an additional bus-transmitted channel on the transmitter. Both IBEX controller cables (red and black) must be correctly connected to the receiver.

First, create another channel on the transmitter to control the direction of the motor. This channel should be controlled by a two-position switch.

Futaba/Spectrum:

Use one of the AUX channels and remember the channel number. It is not necessary to limit yourself to only the channels available on your receiver, as RC systems usually send more channels on the bus than the physical number of outputs on the receiver.

Example: if you are using a Spektrum NX6 and a six-channel receiver, you can still use channel 7 (AUX2) to control the reversion function over the SRXL2 bus.

JETI:

Create a new model function in the Model - Function Assignment menu and assign a free two-position switch to it. Then, in the Model - Servo Assignment menu, assign this function to one of the receiver channels (1–16). Again, you can also use channels that are not directly available on the receiver outputs (e.g. 13–16) as they will be transmitted over the EX Bus protocol without restriction.

PowerBox:

Create a new function for the model in the Function menu by pressing the "+" button and assign a two-position control switch to it. Select one of the available output channels (1–16). The position of the switch will be transmitted via the P2Bus to the speed controller.

To activate the motor reverse function in the controller, set the "Controller Mode" "Normal/Reverse" and set the reversal channel from the previous step. You can also fine-tune the brake settings and wait time before reversing when using the "Manual" brake type.

Zkontrolujte funkci: Jakmile přepnete přepínač směru, regulátor aktivuje brzdu a po krátké pauze se motor začne otáčet v opačném směru.

Galvanic isolation

The KAVAN SMART PRO 80 and KAVAN SMART PRO 120/130 controllers have an optically isolated gas inlet. IBEX-200/220 also include galvanic isolation for all signal wires.

Fan control

KAVAN SMART PRO 200/220 includes a controlled output for an external fan (5V, up to 300mA). It is activated when the controller temperature reaches 55°C.

Use only a suitable fan, which is sold as an accessory to the controller. Attach the fan to the heat sink using the screws provided. Connect the fan to the controller output marked "FAN" as shown on the left. The fan is powered by the receiver battery with the voltage stabilized at 5V.

Telemetry and settings

Plug the red data cable into the sensor slot on the JETIBOX / SMART-BOX (or the corresponding receiver). Power it from a 4.5–8.4V battery. You can now safely configure the controller using the arrows on the terminal.

KAVAN SMART PRO controllers are compatible with JETIBOX setting. The JETIBOX menu is divided into five sections:

Current values

- displays fresh telemetry values along with minimums and maximums.

Available telemetry: voltage, current, capacity, speed, power (percentage), temperature.
If a Motor-ID chip is connected, the motor identification and temperature will also be displayed.
Reset Min/Max - press the left and right buttons simultaneously to reset all minimums and maximums.

General settings

- basic controller settings

Controller mode - basic controller mode (normal or fast).
Sound after startup - select the melody to be played after the driver is initialized.
When idle - you can activate short repeated beeps to indicate a live motor.
Engine endpoints, engine start, full engine - settings related to decoding the throttle input signal.
Capacity reset - you can choose at which point the capacity and power consumption are reset:

After power-up - the capacity is reset after the controller initialization. However, the capacity from the previous run will be displayed initially until you start the engine.
Voltage change - the capacity is cleared when a battery with a similar (or higher) voltage compared to the maximum battery voltage from the previous run is connected. This means that every time you connect a fully charged battery of the same composition and cell count, the capacity will be cleared.
Manual - capacity and energy are never reset and you must reset manually.

Language - you can select the language of the JETIBOX screen.

Engine settings

- settings related to engine parameters.

Direction, acceleration, timing, starting power, motor type, gear ratio, number of poles
Direction, acceleration, timing, starting power, motor type, gear ratio, number of motor poles - see chapter Motor settings.
Brake related settings - see chapter Brake configuration.
Propeller positioning, PWM positioning, position holding - see chapter Propeller positioning.
Motor enabled (0/1) - motor start can be enabled or disabled based on the logic state of the specific input "IN B.2" (connector pin from left to right: 1 = Hall probe input, 2 = motor enable input, 3 = 3.3V, 4 = GND). If you select "Vst.pin Log0/1", you must always withdraw the throttle before starting the motor. On the other hand, if you select "Autostart Log0/1", the motor will start as soon as the logic value of the input pin allows it and the throttle position is above idle.
Switching - allows you to enable synchronous switching (active brake) or leave the standard controller mode.

Protection

- setting the controller and battery protection.

Low battery - behaviour when the battery is low. Either the engine power will slowly decrease or the engine will shut down immediately. The minimum safe voltage is calculated from the number of cells and the minimum voltage per cell.
Current limiting - enable this function to prevent high current spikes and system overload.
Limit power at 100°C - you can adjust the maximum allowed PWM of the controller after its temperature exceeds 100°C. The model must be operational, but the temperature must no longer increase.

Service

- In this menu you can view the version of the device and reset it to the factory default configuration.

JETIBOX menu structure

EX and P2Bus and Fport telemetry available:

Battery voltage [V]
Motor current [A]
Capacity [mAh]
Speed [RPM]
PWM [%]
Power [W]
Motor running time [s]
Energy [Wmin] - useful function for competitions where total energy is limited (F5B, F5D).
Temperature [°C]
External temperature [°C] - if a motor ID chip is connected, the controller sends the motor temperature as its own telemetry.
Motor status:
0 = Initialization,
1 = Motor running,
2 = Braking,
3 = Positioning started,
4 = Position found.
5 = Position error (propeller moved).

The KAVAN SMART PRO controller is recognized as an "Air-ESC" sensor by default.

Futaba and Multiplex connection

Futaba and Multiplex systems do not offer wireless configuration of connected devices. Telemetry transmission is possible using the following fixed sensor slots:


	Futaba S.Bus2 slot	Note	Slot Multiplex MSB
Speed	2	Select the RPM sensor on slot 2.	6
Current	3	Select the SBS01C current sensor on slot 3.	3
Voltage	4		2
Capacity	5		4
Temperature	6	Select the Temp125 sensor on slot 6.	5
PWM (0–100%)	7	Select the Temp125 sensor on slot 7.	-
Note	Manual detection in menu Linkage - Sensor.		Automatically detected by the transmitter.

PowerBox Telemetry

Since version 1.09, the KAVAN SMART PRO controller is able to recognize the PowerBox P 2Bus telemetry protocol. Connect the telemetry cable (red connector) to the P2Bus port on the receiver. The transmitter will locate the connected sensors as soon as the receiver is switched on. The controller telemetry should then be available within 2.5 seconds. You can now assign telemetry values to any widgets and alarms on the transmitter's desktop. The available telemetry is similar to the Duplex EX telemetry (see above). Configuring the controller via the PowerBox transmitter is not available at this time.

Spectrum Integration

Since version 1.06, Spektrum telemetry support is integrated in a special firmware version. This alternative firmware offers SRXL2 telemetry and TextGen settings. The KAVAN SMART PRO controller is represented in the transmitter by two telemetry devices:

"ESC" displays battery voltage, current, BEC voltage, controller temperature, speed and output power.
"Flight Pack Capacity", which shows the consumed battery capacity.

Connect the throttle cable (black connector) to the Thr receiver port (1). For proper telemetry/setup operation, also connect the telemetry cable (red connector) to the Prog/SRXL2 receiver port. The controller provides only numeric telemetry by default. The text menu (TextGen) is only available after a special start-up procedure:

We assume that the gas and telemetry cables are correctly connected and the transmitter is switched on. Now set the the remote control to the "Full throttle" position.
Switch on the controller either by connecting the drive set or by switching on the external switch.
The motor will start, indicating full throttle pulse detection. After 3 seconds, another beep will announce entry into the programming menu.
You can now fully withdraw the throttle. From the transmitter's main screen, scroll to the right and locate the TextGen menu. If the text menu is activated, the engine will never start to turn. To get the engine running normally again, you must exit the TextGen menu by selecting "Exit" on the main page.
The menu navigation is provided by the transmitter levers - the elevator lever moves the cursor up/down and the aileron lever changes the selected value.
Configuration changes are saved immediately after any value is modified.

Safety information

Always use the KAVAN SMART PRO controller in a dry environment and within the limits of the equipment specified in this manual. Never expose the device to excessive heat or cold outside the operating range.
Ensure sufficient airflow to prevent the controller from overheating.
Never exceed the maximum allowable operating voltage of the controller or the motor.
Do not increase the cable length between the controller and the motor. If you need to extend the wires between the regulator and the battery to more than 30 cm (total), solder several high-capacity Low-ESR capacitors (220-470uF) in parallel to the power wires as close to the regulator as possible. For each centimeter over the specified length of the cables, add 1uF of capacitance per 1cm of length for each ampere of current passing through. At 10cm over the limit for 100A current, connect 1000uF capacitors.
Always use high quality connectors in good condition. If there are any visible signs of wear, replace them.
Always remove the propeller before making any changes to the drive setup.
Never disconnect the controller from the battery while the motor is spinning.
Do not remove the packaging and heat sink from the unit or attempt to make any changes or adjustments. Doing so may result in complete destruction and denial of any warranty claims.
Always check the polarity of the connections. Never reverse the polarity - this could lead to complete destruction.

Firmware updates

Firmware updates for KAVAN SMART PRO controllers are uploaded from a PC via USB. The required programs and files are available at www.mavsense.com.

Install the MAV Manager software and drivers for the USB interface on the PC. Check the system requirements.

Make sure the flight battery is disconnected and the KAVAN SMART PRO controller is unpowered.
Connect the USB interface to your computer, start the MAV Manager - Updater and select the correct COM port.
Connect the IBEX controller as shown below - use the red (telemetry) port. The controller will be automatically detected.
Select the correct *.BIN file and press the Update button.

Configuration via computer

It is possible to use the MAV Manager software (version 1.4.0 and newer) to conveniently configure all controller parameters, display real-time telemetry or backup the configuration. The program menu contains four buttons in the upper toolbar:

Reload - forces a reload of the configuration from the controller.
Import - imports the settings from a file. If you have several controllers and want to have all of them be identically configured, simply import the same settings file into each controller.
Export - exports the settings from the controller to a file. You can easily create a backup configuration that will be stored on your PC. After creating a backup, you can easily experiment with the controller settings and later revert back to the original configuration by pressing the "Import" button and selecting the original saved file.
Default settings - resets the controller to the factory default settings and reloads the entire configuration.

Connect the controller to a computer using the USB interface. It will be automatically detected by the MAV Manager.

The controller properties are available by pressing the "Configure" button.

Real-time telemetry with min/max values. MAV Manager is also capable of creating a log file from real-time telemetry data that can be viewed, analyzed, imported and exported.

Engine Settings. Whenever a configuration change is made, the new value is immediately transferred to the controller and stored in memory. No additional confirmation is required. For safety reasons, some parameters are only applied after the motor has stopped.

Warranty

The product is warranted for 24 months from the date of sale provided it has been operated in accordance with these instructions, at the prescribed voltage and is not mechanically damaged. Always enclose proof of purchase when claiming the product. Warranty and post-warranty service is provided by the manufacturer.

Distributor

KAVAN Europe s.r.o.

Doubravice 110, 533 53 Pardubice, Czech Republic.

E-mail: info@kavanrc.com | Web: www.kavanrc.com | +420 466 260 133

Manufacturer

MAV Sense s.r.o.

E-mail: info@mavsense.com | Web: www.mavsense.com

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 safeguarding the environment. [22.05 13:20] Natálie Marková