Project Files of 60A Brushed ESC Library for Proteus Simulation

60A BRUSHED ESC LIBRARY FOR PROTEUS SIMULATION - V1.0 (a 60 A brushed RC car ESC, with a pop-up)
Designed by The Engineering Projects
www.TheEngineeringProjects.com

IMPORTANT LINKS
Article (read it first - pictures, step by step, every feature explained):
  https://www.theengineeringprojects.com/2026/11/60a-brushed-esc-library-for-proteus.html
Report a bug or suggest a feature (our forum):
  https://www.theengineeringprojects.com/forum/category/motor-driver-proteus-library
The demo runs on our Arduino UNO V4.0 (included) - working LEDs, RESET and a
built-in serial monitor, no Virtual Terminal to wire - its own article:
  https://www.theengineeringprojects.com/2026/10/arduino-uno-library-for-proteus-v40.html
The demo drives our 540 RC Motor library (a SEPARATE library - install it too):
  https://www.theengineeringprojects.com/2026/11/540-rc-motor-library-for-proteus.html
Support us (the libraries are free):
  https://www.theengineeringprojects.com/donate

FILE STRUCTURE
60A-Brushed-ESC-TEP-v1.0/
|-- Proteus Library Files/
|   |-- ArduinoV4TEP.LIB                              201.9 KB   TEP Arduino boards V4.0 (UNO) -> LIBRARY
|   |-- TEPESC60.LIB                                   13.2 KB   the library -> LIBRARY folder
|-- Proteus Model Files/
|   |-- TEPARDUINO.DLL                                883.5 KB   the Arduino board model -> MODELS folder
|   |-- TEPESC60.DLL                                  317.5 KB   the model -> MODELS folder
|-- Proteus Simulation/
|   |-- ESC60_Demo.hex                                 14.8 KB   the demo firmware
|   |-- ESC60-RC540-Car-ArduinoUnoV4.pdsprj            19.8 KB   the demo project
|   |-- TEPARDUINO.DLL                                883.5 KB   copy of the board model
|   |-- TEPESC60.DLL                                  317.5 KB   copy of the model
|-- Arduino Code/
|   |-- ESC60_Demo/ESC60_Demo.ino                       3.7 KB   the demo sketch (source of the .hex)
|-- README.txt                                        ~14.9 KB   this file
Total: 2.61 MB (unzipped). The C++ source code of the models is not included.

WHAT IS IT?
A 60 A brushed electronic speed controller (ESC) for RC cars, drawn at true scale (36.5 x 32 mm, the
waterproof case of the common
60 A brushed car ESC; our own drawing, no maker's mark): the throttle from an RC pulse, forward,
brake and reverse through an H-bridge.
  * Modelled from the maker's manual of the common 60 A brushed ESC: 60 A / 360 A forward, 30 A /
    180 A reverse, a 1 mohm / 2 mohm bridge,
    2 - 3S LiPo or 5 - 9 NiMH, a 3 A / 6 V switch-mode BEC.
  * The start of the real ESC: it finds the battery (1 / 2 / 3 short beeps for NiMH / 2S / 3S),
    calibrates the neutral when the throttle
    sits there for 3 s, gives one long beep and is ready.
  * Three running modes (a jumper): Fwd / Br / Rev with the double-click reverse (the first push
    back brakes; the next push back reverses
    only once the motor has stopped), Fwd / Br, Fwd / Rev.
  * The protections: low-voltage cut-off (halved, then cut), over-heat (100 C, back under 80 C),
    throttle signal loss (0.1 s).
  * The red LED on the sheet: off at neutral, blinking part way, solid at full throttle; the beeps
    on the PC's speaker.
  * Click it at Run for the pop-up: the throttle pulse on its scale, the H-bridge with its switches
    and the current's path, the state
    machine, graphs, an event log and a check page.
The body is drawn as on the real part and to true scale against our Arduino.
The TEP signature and the pop-up are TEP additions.

ONE DEVICE (search "ESCBRUSHED" in Pick Devices):
  ESCBRUSHED60TEP  "60A Brushed ESC V1.0" in TEPESC60.LIB (Electromechanical > Motor Drivers),
  prefix U, model TEPESC60.DLL (mixed).
                   Pins B+ / B- (the battery), S (the throttle pulse) and BEC (6 V out) on the left,
                   M+ / M- (the motor) on the right.
                   The name starts with ESC so that it sorts after the embedded ARDUINO UNO V4.0.
The demo's motor is our 540 RC Motor (RCMOTOR540TEP in TEPRC540.LIB / TEPRC540.DLL): a separate
library - install it from its own package.

THE POP-UP
Click the part at Run. Tabs:
    ESC        the throttle pulse on its scale (forward, deadband, brake / reverse zones, the
    calibrated points), the H-bridge (Q1 - Q4 on,
               switching or off, the current's path), the state machine (self-test, calibrate,
               ready; forward, neutral, brake, reverse;
               the protections), and eight live values: pulse, output, motor, battery, BEC,
               temperature, power, peak currents.
    Graphs     the live values over the last 2, 6 or 15 s. Live / Freeze.
    Event log  every change and warning; filters All / Changes / Warnings, Pause, Clear
    Check      what the part is doing and what to look at, each with a verdict (green = fine, amber
    = check, red = wrong)
    Settings   theme, text size, open at Run, window size
    Help       report a bug, suggest a feature, article, updates, donate, forum; Copy diagnostics
    for a bug report

TEST STATUS
V1.0: verified in Proteus 8.5 on 8 Nov 2026 (the demo project as shipped: an A4 sheet, an Arduino UNO V4.0).
What the runs showed (the model's own numbers and the sketch's monitor):
  * The project loads and starts cleanly; the 19 s program runs in about five minutes on our PC
    (with both pop-ups open).
  * The start: POWER ON at 7.40 V - a 2S LiPo found (2 short beeps); CALIBRATED at 3.12 s: neutral
    1500 us (full forward 2000, full
    back 1000), one long beep; READY at 3.62 s.
  * Forward: 1750 us = 48 % - 3.58 V average to the motor, 3.4 A, the car at 13.8 km/h; 2000 us =
    100 % - 7.39 V, 5.9 A (6.0 A from
    the battery), the car at 29.0 km/h with the motor at 23,088 RPM.
  * The first push back (1000 us at 8.58 s) only brakes: the motor stopped 1.28 s after the brake
    began (the car in 3.50 m), 74 A at the
    peak of the braking. Back to neutral: the motor stopped, reverse armed; 1200 us = REVERSE 59 %:
    -4.34 V, 4.0 A, 16.8 km/h backwards.
  * Neutral at 13.08 s: the car rolls on backwards (3.88 V back-EMF); back again at 13.48 s while it
    still rolls: BRAKE, no reverse
    (the double-click guard) - the motor stopped 0.88 s later.
  * 1900 us = forward 79 %: 5.87 V, about 60 A for the start from rest; the Servo detached at 17.0
    s: SIGNAL LOST at 17.16 s - the
    output cut, the car coasts; the signal back at 18.59 s.
  * The pop-up: ESC (the pulse on its scale, the H-bridge, the state machine, eight values), Graphs,
    Event log, Check - all four
    followed the run; the LED on the sheet solid red at full throttle.

INSTALLATION (about 2 minutes)
1. Close Proteus. Extract the WHOLE ZIP to a normal folder (e.g. Desktop).
2. Copy everything in "Proteus Library Files" (TEPESC60.LIB and our Arduino library V4.0,
ArduinoV4TEP.LIB, with the ARDUINO UNO V4.0 used by the demo) to the LIBRARY folder of Proteus, for
example:
     C:\Program Files (x86)\Labcenter Electronics\Proteus 8 Professional\LIBRARY
   (use the folder that already holds Proteus's own .LIB files).
3. Copy TEPESC60.DLL and TEPARDUINO.DLL from "Proteus Model Files" to the MODELS folder (...\Proteus
8 Professional\MODELS).
4. Delete TEPESC60.IDX from the LIBRARY folder if it is there (Proteus makes a new index).
5. Start Proteus. In Pick Devices (P) search "ESCBRUSHED".

RUN THE DEMO
"Proteus Simulation\ESC60-RC540-Car-ArduinoUnoV4.pdsprj" (an A4 sheet) - keep the .hex file and the
DLLs beside the project.
  ARD1:   Arduino UNO V4.0 running ESC60_Demo.hex, its serial monitor built in (window "TEP Arduino
  UNO - ARD1"): the receiver.
  U1:     the ESC: S = D9 (the Servo library's pulse), B+ = +7.4V (a 2S LiPo), B- = GND, M+ / M- to
  the motor; MODE FBR, BATTERY LIPO.
  M1:     our 540 RC motor in a 1/10 car (LOAD CAR).
  1. Neutral from the start: 2 short beeps (2S LiPo), the neutral calibrated in 3 s, one long beep.
  2. Half and full forward; full back (the first push back brakes the car to a stop); neutral; back
  again (now it reverses).
  3. Neutral while reversing, back again at once (the motor still turns: it brakes); forward; the
  pulses stopped (the failsafe).
Closed the monitor? Click the UNO's USB port.

WIRING (the same in Proteus and on a real board)
  S to the receiver's throttle channel or an Arduino pin (Servo.attach, writeMicroseconds 1000 -
  2000); the ESC's black receiver wire
  (B- inside) to the Arduino's GND; B+ / B- a 2 - 3S LiPo or 5 - 9 cell NiMH pack; M+ / M- the
  brushed motor (swap them to reverse it).
REAL HARDWARE:
 * Never connect the battery the wrong way round: the real ESC is damaged at once.
 * The BEC's red wire powers the receiver (6 V): with an Arduino on USB, leave it off or use it for
   the servos only.
 * Hold the throttle at neutral while the ESC starts: it calibrates there - a stick off neutral and
   it waits, without the long beep.
 * Use the transmitter's failsafe (throttle to neutral); the ESC also cuts after 0.1 s without
   pulses.

THE DEMO SKETCH ON THE SERIAL MONITOR (ESC60_Demo V1.0, 9600 baud)
The sketch runs its program, then waits. Type a pulse width to drive it yourself (it ends the
program):
  1750    forward (half)        2000    full forward        1500    neutral        1000    full back
  d    detach (no pulses)
EXPECTED MONITOR OUTPUT
  TEP 60A Brushed ESC demo - the throttle pulse on D9
  0.00 s  1500 us: neutral - the ESC calibrates (3 s)
  4.50 s  1750 us: forward, half stick

PROPERTIES (double-click the part > Edit Properties)
  Running mode (MODE)                  FBR (Fwd / Br / Rev, double-click reverse), FB (Fwd / Br), FR
  (Fwd / Rev, single click)
  Battery type (BATTERY)               LIPO (2 - 3 cells, found from the voltage) or NIMH
  Air temperature (AMBIENT)            C (25)
Every run starts again from the properties.

LINKS.INI (OPTIONAL)
The Help page cards of the pop-up open web pages. To point them somewhere else without a new DLL,
put a text file named links.ini next to TEPESC60.DLL with lines KEY=URL, for example:
  ARTICLE=https://www.theengineeringprojects.com/...
Keys: WEBSITE, FORUM, BUG_REPORT, FEATURE_REQUEST, ARTICLE, USER_GUIDE,
UPDATE_CHECK, DONATE. Only http:// and https:// links are used; lines starting
with # are comments.

TROUBLESHOOTING
* No long beep, WAITING: the throttle must sit at neutral (1.3 - 1.7 ms) for 3 s after the power
  comes on.
* It brakes but will not reverse: the double-click - back to neutral, let the motor stop, push back
  again (or set MODE FR).
* SIGNAL LOST: no pulse on S for 0.1 s (the Servo detached, a loose wire) - the output is cut until
  pulses return.
* LOW VOLTAGE: under the threshold for 2 s - the power is halved, then cut until the power is
  cycled.
* The part is not simulated: TEPESC60.DLL is missing from MODELS and from the project folder. No UNO
  / no monitor window: TEPARDUINO.DLL is missing, or click the UNO's USB port.

BUG REPORTS AND FEATURE REQUESTS
Please post them in our forum with a screenshot, the Serial Monitor text, the
simulation log and the pop-up's Copy diagnostics text:
  https://www.theengineeringprojects.com/forum/category/motor-driver-proteus-library

SUPPORT US
This library is free. If it saves you time, please support our work:
  https://www.theengineeringprojects.com/donate

WEBSITE
  https://www.theengineeringprojects.com/

LICENCES AND THIRD-PARTY NOTES
* The model (TEPESC60.DLL), the symbols and artwork, the other parts of ours in the demo and the
  Arduino Library V4.0 (ArduinoV4TEP.LIB / TEPARDUINO.DLL, with its built-in TEP Serial Monitor
  Advance) are made by The Engineering Projects. The models use only standard Windows libraries; no
  Visual C++ redistributable is needed.
  The C++ source code is not included.
* Arduino UNO V4.0 (ArduinoV4TEP.LIB / TEPARDUINO.DLL, our Arduino Library V4.0 - its
  microcontroller is Proteus's own AVR model): The Engineering Projects,
  https://www.theengineeringprojects.com/2026/10/arduino-uno-library-for-proteus-v40.html
* The .hex file is built from the demo sketch and the Arduino AVR core 1.8.6, which includes
  LGPL-licensed code; its source code is available at
  https://github.com/arduino/ArduinoCore-avr/tree/1.8.6
* Proteus is a product of Labcenter Electronics and is not included. Arduino is a trademark of Arduino SA.
  This library is not made or endorsed by Arduino or Labcenter.

REBUILDING THE FIRMWARE (OPTIONAL)
The HEX file is supplied; Arduino IDE is not needed to run the demo. To edit the sketch, open
Arduino Code\ESC60_Demo\ESC60_Demo.ino, select Arduino Uno and use Sketch > Export Compiled Binary.
Replace the simulation's .hex with the exported HEX. The sketch needs 5,374 bytes of flash and 724
bytes of RAM.

MODEL SCOPE AND LIMITS
Modelled: the RC pulse (every edge), the start-up (battery found, the beeps, the 3 s neutral
calibration), the throttle with a 3 %
deadband, the three running modes and the double-click reverse; the bridge averaged (forward /
reverse resistance, the brake through the
low sides returning energy to the battery), the battery current, the BEC, the low-voltage, over-heat
and signal-loss protections, the LED.
Not modelled: the PWM ripple itself, punch and drag-brake settings, the motor's inductance, the
reverse-polarity damage, the cooling fan.

VERSION
TEP 60A Brushed ESC library V1.0 (Nov 2026). Device ESCBRUSHED60TEP (TEPESC60.LIB / TEPESC60.DLL).
Demo sketch ESC60_Demo V1.0. Demo board: ARDUINO UNO V4.0 (TEP Arduino Library V4.0) with its
built-in serial monitor; motor: our 540 RC Motor library.