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Service Advisory 2010-03: Phoenix Ice HV ESC Heatsink Spacer Thickness Inspection

August 26, 2010

Advisory applies to: Castle Phoenix Ice HV 60, HV 80, and HV 120 amp ESCs

Correct. Slight gap between opto isolators and spacer.

A thin aluminum spacer is used to physically connect electronic components of the Phoenix Ice HV controllers listed above to the interior surface of the extruded heatsink. Some spacers' thickness may be out of spec creating a slight gap between the ESC control board and the heatsink. In extreme situations, this may allow the control board to disengage from the power board of the controller. Castle therefore advises all users of the listed controllers to check their Phoenix Ice HV controllers to determine if their controller has the proper spacer using the following simple procedure. The incorrect spacers were likely used in Q2 and Q3 2010. Units made prior to that time are most unlikely to have this issue. As the inspection for this matter is so simple, we suggest all users perform the test described below.

Incorrect. Space between opto-isolators and spacer.

Phoenix Ice HV 120 Control Board Spacer Identification Procedure:

  1. Disconnect the ESC from all power sources.
  2. Ensure that person testing the controller is not carrying a static charge.
  3. Locate the throttle wire exit point on the ESC. Peel the upper and lower labels of the controller away from the plastic end cap on that end of the controller.
  4. Slide the end cap away from the controller to allow visual inspection of the interior of that end of the controller.
  5. Lightly press on the control board at the point where the throttle wires are attached to ensure that the control board is properly seated in the connector.
  6. Check to see if there is excessive space between the aluminum spacer and the control board. We suggest using a business card as a feeler gauge. Try to slide a corner of the business card between the light beige colored components (opto-isolators) on the control board and the spacer.

Test to see if a business card will fit between spacer and components.

Try to insert a business card between the opto isolators and the spacer. The card will not fit between the opto-isolators and the spacer (not between the opto isolaters themselves!) if the correct spacer is used. If the card does fit, as in the photo above, the wrong spacer is installed in the ESC.

a. If there is a space: please discontinue operation of the controller and send the controller back to Castle for repair. There are no charges for these repairs. Click here and fill out the Warranty RMA form.

b. If there is no space: and assuming that there are no other forms of damage to the ESC, the ESC is cleared for operation. Please secure plastic cover in it's proper position with the product labels.

Fine Print:
This advisory shall not serve to modify any of the terms of the Castle ESC warranty.

Repair Procedure:
To send your ESC in for repair, click on the "Send In Repair" button on the bottom right and following these steps.

  1. Enter your information.
  2. Print the order confirmation.
  3. Ship to Castle via a traceable delivery service:

    Castle Creations, Inc.
    Attn: Repairs
    540 North Rogers Road
    Olathe, Kansas 66062

Please be sure to include a copy of the order confirmation in your package.

Castle Creations cannot be held responsible for lost or damaged shipments, or packages that do not arrive at Castle. Please be sure to properly package your item (putting your ESC in a white envelope and dropping it in the mailbox is not a good idea), and use adequate postage. Packages shipped with incorrect postage will be refused.

If you have any questions or would like to check the status of a repair please contact us at kEncEmailsfqbjstAdbtumfdsfbujpot/dpn.