NOVAK CYCLONE User manual

OPERATING INSTRUCTIONS CYCLONE & CYCLONETT
TT
TCC
CC
CSPECIFICATIONS
Input Voltage 4-7 cells (1.2 volts DC/cell)
Case Width 1.73 inches [4.40 cm]
Case Depth 1.10 inches [2.79 cm]
Case Height 0.79 inch [1.99 cm]
Weight (w/o heat sinks) 1.42 ounces [40.26 g]
On-Resistance @ Transistors 0.00058Ω
Rated Current 480 amps
Braking Current 160 amps
BEC Voltage / Current 6.0 volts DC / 3.0 amps
Wire Size (Battery/Motor) 12 gauge (Super-Flex 12™)
Wire Length (Battery/Motor) 9 inches [22.8 cm]
Signal Harness Length 8 inches [20.3 cm]
Minimum Brake Range 0 to 75 % Full Brake
Minimum Drive (% Full Drive) 6.0-6.0-1.5 (TC: 1.0-2.0-3.0)
Deadband (% Full Throttle) 6.0-6.0-4.0 (TC: 7.0-3.0-3.0)
Drive Frequency (kHz) 5.86-7.8-15.6(TC:15.6-11.7-7.8)
Brake Frequency (kHz) 3.9-5.86-3.9(TC:3.9-5.86-7.8)
@ 25°C transistor
junction temp.
The Novak Cyclone and CycloneTC touring edition are all-
digital, microprocessor-based ESC’s (Electronic Speed Controls)
using advanced components and the best HYPERFET III
transistors to deliver the highest performance with the
smallest size and lightest weight. Each have three user-
selectable throttle profiles and the ability to store a fourth
custom profile created by the optional Pit Wizard (#1035)
or Profile Software (#1030), giving you extreme flexibility.
Novak’s Constant Force Braking provides more effective
braking at lower motor RPMs, while a minimum brake
adjustment pot lets you set initial braking from 0-75%.
Low-resistance solder posts and Super-Flex 12™ wire give
minimal voltage drop and high current handling, while
allowing quick and easy wire replacement and positioning.
Novak’s Polar Drive Circuitry gives you increased power
and reduced operating temperatures. This means even
smoother throttle response, increased radio system range,
quicker acceleration, and longer run times.
Other features include the original One-Touch Set-Up™,
Radio Priority & Digital Anti-Glitch Circuitry™, the Novak
Input Plug System™, a heavy-duty BEC to handle high
power servos, and low-voltage operation down to 2 volts.
Included with the Cyclone and CycloneTC is the Novak
Input Plug SystemTM to convert the Futaba J style signal
harness to be compatible with Sanwa, KO, Kyosho, JR,
and Hitec radios. Refer to Figures 1 through 3 to convert plug.
Sanwa (A) KO Kyosho (KYO) JR/Hitec/AirZ
FIGURE 1 With a small standard screwdriver, press on
each of the three metal prongs until the wires are easy to
remove. Remove wires.
FIGURE 2 With the screwdriver, carefully lift each of the
metal locking tabs to the angle shown.
STEP 1
CHANGING THE INPUT PLUG
Part#1767
FIGURE 3 Insert each pin into the correct plug slot. Each
pin should "click" into place.
(Sanwa plug shown)
WHT = White wire terminal (signal)
BLK = Black wire terminal (negative)
RED = Red wire terminal (positive)
CAUTION Improperinstallation ofthese wiresmay cause
damage to the receiver, servo, and speed control.
Part#1765
The locking tab must not extend
outside the plastic plug housing.
ACCESSORIES
MOTOR CAPACITORS
To prevent radio interference, you must have three 0.1µF
capacitors properly installed on every motor. Three 0.1µF
(50v) capacitors are included for one motor. Additional
0.1µF (50V) capacitors are available in Novak kit #5620.
Refer to Step 3 for motor capacitor installation instructions.
SCHOTTKY DIODES
The Cyclone and CycloneTCTC
TCTC
TC have an internal Schottky
diode. External Schottky diodes are also included, and
should be used for optimum ESC, braking, and motor
performance. Refer to Step 3 for installation instructions.
Additional Schottky diodes are available in Novak kit #5640.
HEAT SINKS
Heatsinks arenot requiredwith the Cyclone or CycloneTCTC
TCTC
TC.
However,
added cooling from heat sinks can increase
efficiency. An optional Heat Sink Set is available as Novak
kit #5407. Heat sinks are recommended
for heavy load
applications and set-ups with limited air
circulation, or if
the transistors get excessively hot during
operation.
POWER CAPACITORS
An external power capacitor is included, and must be
used to maintain cool and smooth operation.
Refer to Step 3 for installation instructions.
AdditionalPower Capacitors are available inNovak kit#5670.
PRECAUTIONS
• WATER & ELECTRONICS DON’T MIX! Do not operate
model in or around water. Never allow water, moisture, or
other foreign materials to get inside the ESC.
• 4 to 7 CELLS ONLY Never use more than 7 cells (8.4 volts
DC) in the main battery pack.
• MOTOR CAPACITORS REQUIRED Three0.1µF (50V) ceramic
capacitors must be properly installed on every motor to
prevent radio interference.
• POWER CAPACITOR REQUIRED An external power
capacitor must be used to ensure the highest efficiency and
best protection for your Cyclone or CycloneTC.
•
NO REVERSE VOLTAGE! Reverse battery polarity can damage
speed control––Disconnect battery immediately.
• DON’T LET TRANSISTOR TABS TOUCH Never allow the
two transistor tab banks to touch each other or any
exposed
metal. The short circuit will
damage the ESC.
•
DISCONNECT THE BATTERIES Always disconnect the battery
pack from the speed control when not in use.
• TRANSMITTER ON FIRST Always turn on the power of
your transmitter first so that you will have control of the
radio equipment when you turn on the speed control.
•
DON’T GET BURNT! Transistor tabs can get hot, so be careful.
If transistor tabs get extremely hot use optional heat sinks.
• INSULATE WIRES Always insulate exposed wiring with heat
shrink tubing to prevent short circuits.
1. DETERMINE BEST ESC MOUNTING LOCATION
Speed control should be positioned away from the
receiverand antennaas shownin set-upphoto (back page).
Choosea mountingposition thatwill keeppower wires
away from the receiver and antenna. Choose position
that will provide maximum airflow through transistor
tabs or heat sinks to allow for proper cooling.
2. INSTALL THE SPEED CONTROL
Use the included double-sided tape to mount ESC.
3. INSTALL THE ON/OFF SWITCH
Determine a convenient place to mount the switch
where it will be easy to get to. Mount switch using a
piece of double-sided tape or with a screw through
the hole in the base of the switch housing.
4. INSTALL THE RECEIVER AND ANTENNA
Mount receiver as far from ESC, motor, power wires,
battery, and servo as possible. These components all
emit radio noise when the throttle is being applied.
On graphite or aluminum, it may help to place the
receiver on edge with the crystal and antenna as far
above the
chassis as possible. Mount the antenna close
to the receiver
and trail any excess wire off the top of
the antenna mast.
Cutting or coiling excess wire will reduce radio range.
STEP 2
MOUNTING INSTRUCTIONS
STEP 3
HOOK-UP INSTRUCTIONS STEP 3 HOOK-UP INSTRUCTIONS (Cont.)
To install capacitor along the ESC’s power wires:
Install capacitor as close to the speed control as possible.
Make a small splice on the black and red power wires.
Solder the negative lead (–) to the splice on the black wire.
Solder the positive lead (+) to the splice on the red wire.
Secure power capacitor to power wires with included
large heat shrink to insulate and protect from vibration.
4. CONNECT SPEED CONTROL TO THE RECEIVER
After the proper input plug plastic has been installed
to match the receiver (Refer to Step 1), plug the speed
control into the THROTTLE CHANNEL of the receiver.
5. CONNECT SPEED CONTROL TO THE BATTERY PACK
Cut the BLACK wire to the desired length and strip
about 1/8”-1/4” of insulation off each end. Solder to
the negative side of a completely charged 4 to 7 cell
battery pack and the other end to the BLK solder post.
Cut the RED wire to desired length (to go from ESC to
battery positive to motor) and strip about 1/8”-1/4” of
insulation off each end. Strip a short section of insulation
(1/4”-3/8”) from the middle section of the RED wire
where it will attach to positive of battery pack. Solder
the stripped section of RED wire to positive of battery
pack and one end to the RED solder post.
NOTE: Prolonged or excessive heating of solder post can
result in the post desoldering from PCB and short-circuiting.
6. CONNECT SPEED CONTROL TO THE MOTOR
Solder the free end of the RED wire to positive motor tab.
Cut the BLUE wire to desired length and strip about
1/8”-1/4” of insulation off each end. Solder to the
negative tab of the motor and to the BLUE solder post.
TIP: Twisting the BLUE & RED motor wires one or two times
around each other as they go to motor can help reduce any
radio noise that may be emitted from the power wires.
7. USING PLUGS FOR BATTERY & MOTOR CONNECTION
High-quality/low-resistance connector plugs, such as
Dean’s Ultra Plugs, can also be used to connect the
motor and battery pack. While connectors make com-
ponent changes quick and easy, they
will never have
the low resistance of a good solder joint.
Use connectors that can not be connected backwards.
It is good practice to use female connectors on batteries
to avoid shorting the connector and the battery.
If you use connectors for the battery and the motor,
use a male connector on the ESC wires going to the
battery and a female connector on the wires going to
the motor. By doing this, you will avoid plugging the
battery into the motor output of the ESC by mistake.
1. INSTALL MOTOR CAPACITORS
Electric motors generate radio noise that can interfere with
your receiver and cause radio problems. Included in the
accessory kit with the ESC are three 0.1µF (50V) non-
polarized, ceramic capacitors. These capacitors must be
installed on every motor to help reduce noise generated
by the motor and also to prevent possible ESC damage.
Solder 0.1µF (50V) capacitors between:
• POSITIVE (+) motor tab & NEGATIVE (–) motor tab.
• POSITIVE (+) motor tab & GROUND tab*.
• NEGATIVE (–) motor tab & GROUND tab*.
*If motor has no ground tab, solder the capacitors to motor can.
Negative (–) motor tab
0.1 µ F Capacitors
Schottky diode
Positive (+) motor tab
Ground / motor can
Extra 0.1 µ F capacitors are available in Novak kit #5620.
2. INSTALL SCHOTTKY DIODE
Solder the lead CLOSEST to the silver stripe on the body
of the Schottky diode to the POSITIVE (+) motor tab.
Solder the lead OPPOSITE the silver stripe on the body
of the Schottky to the NEGATIVE (–) motor tab.
If installed backwards, a Schottky diode will be destroyed. The
body of a bad diode will normally crack open. Replace only with
Schottky diodes that have a minimum rating of 35 volts / 8 amps.
Schottky diodes are available in Novak kit #5640.
3. INSTALL POWER CAPACITOR
The included power capacitor will drop the speed control’s
operating temperatures by 10-15 ° F, and will help dissipate noise
and voltage spikes from the ESC’s high switching speed.
To allow greater flexibility for your application, you can
install the power capacitor up against the side or back
of the ESC, or heat shrink it along the power wires.
To install capacitor alongside the speed control:
Use included double-sided tape to hold the capacitor
against the side or back of the speed control’s case.
Bendnegative lead (–) {shorter/markedwithstripe} toward the
BLK solder post. Insulate lead with included vinyl tubing.
Solder negative lead
(–) to the BLK solder post.
Bend positive lead (+) {longer/unmarked} toward the RED
solder post. Insulate lead with included vinyl tubing.
Solder positive lead (+) to the RED solder post.
negative lead (–)
with stripe
Insulate leads
with vinyl tubing
Refer to Set-Up photo on back

SET-UP PHOTO
STEP 4
TRANSMITTER ADJUSTMENTS
For proper ESC operation adjust transmitter as follows:
1. Set HIGH ATV or EPA to maximum setting.
[Controls amount of throw from neutral to full throttle]
2. Set LOW ATV, EPA, or ATL to maximum setting.
[Controls amount of throw from neutral to full brakes]
[Reducethis after programming to reduce amount ofbrakes]
3. Set EXPONENTIAL to zero.
[Controls the linearity of the throttle channel]
4. Set THROTTLE CHANNEL TRIM to middle setting.
[Adjustsneutral position/Increases or decreasescoast brakes]
5. SetCHANNEL REVERSING SWITCH to either position.
6. Set ELECTRONIC TRIGGER THROW ADJUSTMENT
to 70% throttle and 30% brake throw (or 7:3).
[Adjusts pistol-grip transmitter’s throttle trigger throw]
7. Set MECHANICAL TRIGGER THROW ADJUSTMENT
to position with 2/3 throttle and 1/3 brake throw.
[Adjusts pistol-grip transmitter’s throttle trigger throw]
Before beginning this step, the speed control should be
connected to the receiver and to a charged 4 to 7 cell
battery pack, and the transmitter should be adjusted.
1. CONNECT THE BATTERY
2.
TURN ON TRANSMITTER THEN THE SPEED CONTROL
Slide the ON/OFF switch to the ON position.
3. PRESS AND HOLD ESC’S 1-TOUCH BUTTON
With the transmitter throttle in the neutral position,
press and hold the SET button on the speed control
until the status LED turns solid red.
4. RELEASE ESC’S 1-TOUCH BUTTON
5. PULL THROTTLE TO FULL-FORWARD POSITION
Hold it there until the status LED turns solid green.
NOTE: The motor will not run during programming even
if it is connected to the speed control.
6. PUSH THROTTLE TO FULL-BRAKE POSITION
Hold it there until the status LED blinks green.
7. RETURN TRANSMITTER THROTTLE TO NEUTRAL
The status LED will turn solid red, indicating that the
throttle is in the neutral position and also that proper
programming has been completed.
The speed control is programmed and ready to race!
If transmitter settings are changed, it will be necessary
to complete the programming sequence once again.
If you experience any problems during programming,
turn off the speed control and repeat programming.
RECEIVER BATTERY PACK
The Cyclone and CycloneTCTC
TCTC
TC speed controls should not require
an external receiver battery pack for most racing situations.
The built-in Radio-Priority Circuity™ provides complete control
of the steering servos even after the main battery pack has
‘dumped’ and can no longer provide the power required to
turn the motor. However, applications with multiple high-
power servos, and some 4-cell set-ups may require an external
receiverbattery pack to preventoverloading or underpowering
of the speed control’s voltage regulator.
1. Plug the external 5 cell nickel cadmium receiver battery
pack into the battery slot of the receiver.
2.
Leave the speed control’s ON/OFF switch in the OFF position .
This switch is not used with this configuration.
3. Use the ON/OFF switch on the external receiver battery
pack to turn the system power on and off.
Note: If using a FET servo with an external receiver battery pack, the
separate power wire from the servo must be connected to the red or
positive servo wire. For this application do not use blue wire from ESC.
TROUBLE-SHOOTING GUIDE
This section describes possible speed control problems,
causes, and solutions.
Steering Channel Works But Motor Will Not Run
• Speed control has thermally shut down––Allow ESC to
cool down––Use milder motor or smaller pinion gear.
• Check motor connections. Check motor and brushes.
• Make sure ESC is plugged into the throttle channel of
receiver. Check throttle channel operation with a servo.
Check wiring color sequence of receiver signal harness.
• Possible internal damage––Refer to Service Procedures.
Receiver Glitches/Throttle Stutters During Acceleration
• Motor capacitors broken or missing––Refer to Step 3.
• Receiver or antenna too close to speed control, power
wires, battery, or motor––Refer to Step 2.
• Bad connections––Check wiring and connectors.
• Motor brushes worn––Replace brushes.
• Excessive current to motor––Use a milder motor or a
smaller pinion gear.
Motor and Steering Servo Do Not Work
• Check wires, receiver signal harness wiring and color
sequence,radio system, crystals, batteryand motorcon-
nectors, and battery pack.
• Possible internal damage––Refer to Service Procedures.
Model Runs Slowly / Slow Acceleration
•
Checkmotor and batteryconnectors––Replace if needed.
• Bad battery or motor––Check operation with another.
• Incorrect transmitter or speed control adjustment––
Refer to Steps 4 and 5.
• Optional external Schottky diode installed backwards
or damaged––Refer to Step 3.
Motor Runs Backwards
• Motor wired backwards––Check wiring and reverse.
• Backwards motor timing––Reverse motor end bell.
ESC Is Melted Or Burnt/ESC Runs With Switch Off
• Internal damage––Refer to Service Procedures.
*For more help call our Customer Service Department.
SERVICE PROCEDURES
Before sending in your Cyclone for service, review the
Trouble-Shooting guide and the instructions. The ESC
may appear to have failed when other problems exist.
PLEASE NOTE: Speed controls that operate normally
when received will be charged a minimum service fee
and return shipping costs.
WHAT TO SEND: Fill out all of the information requested
on the enclosed ESC SERVICE CARD (also available on
website) and return it with your speed control.
WARRANTY WORK: Forwarranty work, you MUST CLAIM
WARRANTY on the ESC SERVICE CARD and include a valid
cash register receipt with the purchase date on it, or an
invoice from previous service work. If warranty provisions
have been voided there will be a service charge.
SERVICE COSTS: Customer is responsible for all service
costs (parts, labor, and shipping/handling charges).
See
ESC SERVICE CARD for payment and shipping options.
ADDITIONAL NOTES:
• The custom fourth profile may be lost during repair.
We suggest storing it in the Pit Wizard or Profile Software.
• Novak Electronics, Inc. does not make any electronic
components(transistors, resistors,etc.) availablefor sale.
• To provide the most efficient service to our customers, it
isnot our policy to contactcustomers by phone or mail.
• Hobbydealers/distributors arenot authorizedto replace
speed controls thought to be defective.
• If a hobby dealer sends your speed control for service,
submit a completed ESC SERVICE CARD to the dealer
and make sure it is sent with the speed control.
PRODUCT WARRANTY
Novak Electronics, Inc. guarantees the Cyclone and CycloneTCTC
TCTC
TC to be
free from defects in materials or workmanship for a period of 120
days from original date of purchase (verified by dated, itemized sales
receipt) . Warranty does not cover incorrect installation, components
worn by use, damage from using fewer than 4 or more than 7 cells
(1.2 volts DC/cell) input voltage, short-circuiting heat sinks, cross-
connection of battery/motor, reverse voltage application, damage
resulting from thermal overload, damage from incorrect installation
of FET servo or receiver battery pack, damage from excessive force
while installing heat sinks, not installing three 0.1µF(50V) capacitors
and a power capacitor on the motor, splices to input or switch
harnesses, damage from excessive force when using SET button or
BRAKE pot or from disassembling case, tampering with internal
electronics, allowing water, moisture, or any other foreign material
to enter ESC or get onto PC board, incorrect installation of alternate
input plug plastic, allowing exposed wires or solder posts to short-
circuit, or any damage caused by a crash.
In no case shall our liability exceed product's original cost. We reserve
the right to modify warranty provisions without notice.
Because Novak Electronics, Inc. has no control over the connection
and use of the speed control, no liability may be assumed nor will
be accepted for damage resulting from the use of this product. Every
ESC is thoroughly tested and cycled before leaving our facility and
is, therefore, considered operational. By the act of connecting/operating
ESC, the user accepts all resulting liability.
CUSTOMER SERVICE
CUSTOMER SERVICE HOURS (PST)
Monday-Thursday: 8:00am-5:00pm
Friday: 8:00am-4:00pm (closedeveryotherFri.)
[phone] • FAX [phone]
©1999 Novak Electronics, Inc. • All Rights Reserved
No part of these operating instructions may be reproduced without the
written permission of Novak Electronics, Inc.
All Novak speed controls are designed and manufactured in the U.S.A.
Cyclone™, CycloneTCTC
TCTC
TC ™, HYPERFET III™, Polar Drive™, One-Touch Set-
Up™, Radio Priority Circuitry™, Digital Anti-Glitch Circuitry™, and Input
Plug System™ are all trademarks of Novak Electronics, Inc.
Printed in the U.S.A. 1/2000 • #IM-1767-3
STEP 7
MINIMUM BRAKE ADJUSTMENT
The BRAKE pot on the Cyclone and CycloneTCTC
TCTC
TC allows you to
adjust the percentage of total braking power applied with the
initial trigger movement in the brake direction. Refer to above
illustration for indication of Minimum Brake Value.
• Turning BRAKE pot clockwise, increases amount of minimum
brakingup toa maximum of 75% of the total brake force.
• Turning BRAKE pot all the way counter-clockwise, sets
the amount of minimum braking at the lowest value of
0.39%, or 1/256th (one step) of the total brake force.
STEP 5
SPEED CONTROL PROGRAMMING
STEP 6
THROTTLE PROFILE SELECTION
FET SERVO CONNECTION
The Cyclone and CycloneTCTC
TCTC
TC speed controls are wired for con-
necting a FET servo that requires seperate power connection.
The fourth wire from the servo is connected to the small blue
24 gauge silicone wire exiting the ESC along with the signal
and switch harnesses. This wire supplies 6 volts DC to the
servo, and is controlled by the ESCs ON/OFF switch.
Be sure to install the 10µH inductor (supplied with servo) in
series with the blue FET wire as shown below.
NOTE: Do not allow the blue FET servo wire to contact the battery
or any condutive surfaces, as this may cause damage to the speed
control and will void the warranty.
NOVAK ELECTRONICS, INC.
18910 Teller Avenue
Irvine, CA 92612
www.teamnovak.com
Mount switch where it
will be easy to get to. Keep receiver and antenna
away from motor, servo,
battery, and power wires.
Red wire
(battery &
motor positive)
Tip: Twist motor
wires to reduce
radio noise!
Trail excess wire
off antenna mast.
(Do not cut or coil)
Blue wire
(motor negative)
Black wire
(battery negative)
(–)
(–)
(+)
(+)
TheCyclone and CycloneTCTC
TCTC
TC allowyou to choose between three
user-selectable throttle profiles that are programmed at the
factory. This chart gives the specifics of each profile:
% kHz % kHz
1 Stock 6.0 5.86 6.0 3.90 OFF
2 Drag Brake 6.0 7.80 6.0 5.86 ON
3**Modified 7.0 15.60 1.5 3.90 OFF
1 **World Cup 7.0 15.60 1.5 3.90 OFF
2 High Traction 3.0 11.70 2.0 5.86 OFF
3 Touring Stock 3.0 7.80 3.0 7.80 OFF
Experiment with each profile to determine which works best for you!
1. TURN ON THE TRANSMITTER
2. TURN ON THE SPEED CONTROL
3. PRESS & HOLD ESC’S 1-TOUCH BUTTON until the status
LED turns solid green. The LED will first turn red, then a
few seconds later it will turn green.
4. RELEASE 1-TOUCH BUTTON and then the status LED will
begin to blink red. The number of times the LED blinks
indicates the profile number selected.
5.
PRESS & RELEASE 1-TOUCH BUTTON TO SELECT PROFILE
Each press will change to the next consecutive profile number.
NOTE: After profile #3, the sequence begins again at profile #1.
6. If 1-TOUCH button is not pushed for about five seconds,
the ESC LOADS THE SELECTED PROFILE INTO MEMORY,
andthe status LED turns solid red, indicating that the speed
control has exited the profile selection mode and is in neutral.
Both ESCs can store a custom fourth profile that is created with either
of the optional programming devices, the Pit Wizard (#1035) or the
Profile Software (#1030). Once a custom profile has been created
and downloaded into the ESC, there will be four profiles to choose
from. Both programming devices come with complete details on creating
your own custom profiles and give you the ability to modify the following
parameters: Neutral Postion, Full Throttle Position, Full Brake Position,
Dead Band Value, Drag Brake Value, Drag Brake Frequency*, Drive
PWMFrequency*,MinimumDriveValue, Brake PWM Frequency*,and
the Drag Brake Toggle. *Adjustable from 122-23,400 Hz
Illustration below shows graphical display of adjustable parameters
Profile
Description
Dead Band
Drive Frequency
Minimum Drive
Brake Frequency
Dr.Brake Toggle
CYCLONE
CYCLONE
TCTC TCTC
TC
(**default)
Fourth wire
from servo.
10
µ H inductor
Blue FET servo wire
from speed control
Blue wire
(FET servo)