OPERATING INSTRUCTIONS

CYCLONE & CYCLONETC
The Novak Cyclone and CycloneTC touring edition are alldigital, microprocessor-based ESCs (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 userselectable 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. Novaks 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. Novaks 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.

SPECIFICATIONS

Input Voltage Case Width Case Depth Case Height Weight (w/o heat sinks) On-Resistance @ Transistors Rated Current Braking Current BEC Voltage / Current Wire Size (Battery/Motor) Wire Length (Battery/Motor) Signal Harness Length Minimum Brake Range Minimum Drive (% Full Drive) Deadband (% Full Throttle) Drive Frequency (kHz) Brake Frequency (kHz) 4-7 cells (1.2 volts DC/cell) 1.73 inches [4.40 cm] 1.10 inches [2.79 cm] 0.79 inch [1.99 cm] 1.42 ounces [40.26 g] 0.00058 @ 25C transistor 480 amps junction temp. 160 amps 6.0 volts DC / 3.0 amps 12 gauge (Super-Flex 12) 9 inches [22.8 cm] 8 inches [20.3 cm] 0 to 75 % Full Brake
6.0-6.0-1.5 (TC: 1.0-2.0-3.0) 6.0-6.0-4.0 (TC: 7.0-3.0-3.0) 5.86-7.8-15.6 (TC: 15.6-11.7-7.8) 3.9-5.86-3.9 (TC: 3.9-5.86-7.8)

Part #1767

Part #1765

STEP 1

CHANGING THE INPUT PLUG
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.

PRECAUTIONS

WATER & ELECTRONICS DONT 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 Three 0.1F (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 controlDisconnect battery immediately. DONT 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. DONT 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.

ACCESSORIES

MOTOR CAPACITORS
To prevent radio interference, you must have three 0.1F capacitors properly installed on every motor. Three 0.1F (50v) capacitors are included for one motor. Additional 0.1F (50V) capacitors are available in Novak kit #5620. Refer to Step 3 for motor capacitor installation instructions.

SCHOTTKY DIODES

The Cyclone and CycloneTC 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.

Sanwa (A)

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.

HEAT SINKS

Heat sinks are not required with the Cyclone or CycloneTC. 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.
FIGURE 2 With the screwdriver, carefully lift each of the metal locking tabs to the angle shown.

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. Additional Power Capacitors are available in Novak kit #5670.

STEP 3

FIGURE 3 Insert each pin into the correct plug slot. Each pin should "click" into place.
(Sanwa plug shown) The locking tab must not extend outside the plastic plug housing.
Refer to Set-Up photo on back

HOOK-UP INSTRUCTIONS

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 0.1F (50V) nonpolarized, 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 0.1F (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 0.1F Capacitors
HOOK-UP INSTRUCTIONS (Cont.)
To install capacitor along the ESCs 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.

WHT = White wire terminal (signal) BLK = Black wire terminal (negative) RED = Red wire terminal (positive)
CAUTION Improper installation of these wires may cause damage to the receiver, servo, and speed control.

STEP 2

MOUNTING INSTRUCTIONS 1. DETERMINE BEST ESC MOUNTING LOCATION
Speed control should be positioned away from the receiver and antenna as shown in set-up photo (back page). Choose a mounting position that will keep power 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.
Schottky diode Positive (+) motor tab Ground / motor can
Extra 0.1F capacitors are available in Novak kit #5620.
2. INSTALL THE SPEED CONTROL
Use the included double-sided tape to mount ESC.
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 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. 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.
3. INSTALL POWER CAPACITOR
The included power capacitor will drop the speed controls operating temperatures by 10-15F, and will help dissipate noise and voltage spikes from the ESCs high switching speed.
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.
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.
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 controls case. Bend negative lead () {shorter/marked with stripe} 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
7. USING PLUGS FOR BATTERY & MOTOR CONNECTION High-quality/low-resistance connector plugs, such as Deans Ultra Plugs, can also be used to connect the motor and battery pack. While connectors make component 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.

SET-UP PHOTO

Mount switch where it will be easy to get to. Keep receiver and antenna away from motor, servo, battery, and power wires.

STEP 6

THROTTLE PROFILE SELECTION
The Cyclone and CycloneTC allow you to choose between three user-selectable throttle profiles that are programmed at the factory. This chart gives the specifics of each profile:
e (* scr *d ip ef t au io lt) n D ea d Ba nd D ri v e Fr eq ue M nc in y im um D ri v Br e ak e Fr eq ue D r.B nc ra y ke To CYCLONE gg le

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 downAllow ESC to cool downUse 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 damageRefer to Service Procedures. Receiver Glitches/Throttle Stutters During Acceleration Motor capacitors broken or missingRefer to Step 3. Receiver or antenna too close to speed control, power wires, battery, or motorRefer to Step 2. Bad connectionsCheck wiring and connectors. Motor brushes wornReplace brushes. Excessive current to motorUse 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, battery and motor connectors, and battery pack. Possible internal damageRefer to Service Procedures. Model Runs Slowly / Slow Acceleration Check motor and battery connectorsReplace if needed. Bad battery or motorCheck operation with another. Incorrect transmitter or speed control adjustment Refer to Steps 4 and 5. Optional external Schottky diode installed backwards or damagedRefer to Step 3. Motor Runs Backwards Motor wired backwardsCheck wiring and reverse. Backwards motor timingReverse motor end bell. ESC Is Melted Or Burnt/ESC Runs With Switch Off Internal damageRefer to Service Procedures. *For more help call our Customer Service Department.

Blue wire (FET servo)

() Black wire (battery negative)
Stock Drag Brake **Modified
% 6.0 6.0 7.0 7.0 3.0 3.0

kHz 5.86 7.80 15.60

% 6.0 6.0 1.5

kHz 3.90 5.86 3.90

OFF ON OFF
**World Cup High Traction Touring Stock

15.60 11.70 7.80

1.5 2.0 3.0

3.90 5.86 7.80

OFF OFF OFF
Experiment with each profile to determine which works best for you!
Tip: Twist motor wires to reduce radio noise!
1. TURN ON THE TRANSMITTER 2. TURN ON THE SPEED CONTROL 3. PRESS & HOLD ESCS 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.
Blue wire (motor negative)
6. If 1-TOUCH button is not pushed for about five seconds, the ESC LOADS THE SELECTED PROFILE INTO MEMORY, and the 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 PWM Frequency*, Minimum Drive Value, Brake PWM Frequency*, and the Drag Brake Toggle. *Adjustable from 122-23,400 Hz Illustration below shows graphical display of adjustable parameters
Red wire (battery & motor positive)
(+) Trail excess wire off antenna mast. (Do not cut or coil)

STEP 4

CYCLONE TC

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: For warranty 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.) available for sale. To provide the most efficient service to our customers, it is not our policy to contact customers by phone or mail. Hobby dealers/distributors are not authorized to 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.

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] [Reduce this after programming to reduce amount of brakes]
3. Set EXPONENTIAL to zero.
[Controls the linearity of the throttle channel]
4. Set THROTTLE CHANNEL TRIM to middle setting.
[Adjusts neutral position/Increases or decreases coast brakes]

STEP 7

5. Set CHANNEL REVERSING SWITCH to either position. 6. Set ELECTRONIC TRIGGER THROW ADJUSTMENT to 70% throttle and 30% brake throw (or 7:3).
[Adjusts pistol-grip transmitters throttle trigger throw]

MINIMUM BRAKE ADJUSTMENT

The BRAKE pot on the Cyclone and CycloneTC 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.
7. Set MECHANICAL TRIGGER THROW ADJUSTMENT to position with 2/3 throttle and 1/3 brake throw.
Turning BRAKE pot clockwise, increases amount of minimum braking up to a 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
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 ESCS 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 ESCS 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 CycloneTC 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 highpower servos, and some 4-cell set-ups may require an external receiver battery pack to prevent overloading or underpowering of the speed controls voltage regulator. 1. Plug the external 5 cell nickel cadmium receiver battery pack into the battery slot of the receiver. 2. Leave the speed controls 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.

PRODUCT WARRANTY

Novak Electronics, Inc. guarantees the Cyclone and CycloneTC 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, crossconnection 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 0.1F(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 shortcircuit, 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.

FET SERVO CONNECTION

The Cyclone and CycloneTC speed controls are wired for connecting 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 10H inductor (supplied with servo) in series with the blue FET wire as shown below.
Blue FET servo wire from speed control 10H inductor Fourth wire from servo.

CUSTOMER SERVICE

CUSTOMER SERVICE HOURS (PST)
Monday-Thursday: 8:00am-5:00pm Friday: 8:00am-4:00pm (closed every other Fri.) (949) 833-8873 FAX (949) 833-1631
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, CycloneTC , HYPERFET III, Polar Drive, One-Touch SetUp, 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
NOVAK ELECTRONICS, INC. 18910 Teller Avenue Irvine, CA 92612 www.teamnovak.com
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.