Novak Ballistic 8 Motor User Manual

MOTOR MAINTENANCE MOTOR MAINTENANCE

• CHECK ALL MOTOR SCREWS for loosening at regular intervals, just like other hardware on your vehicle. Note: The 3 main socket head screws

that hold the motor together may require tightening after a few runs of the motor. Also check the 3 ﬂat head screws securing the end cap on

the back of the motor--DO NOT OVER-TIGHTEN THESE SCREWS.

• CHECK MOTOR BEARING WEAR after extensive use. The motor’s

BALLISTIC

BRUSHLESS MOTOR INSTRUCTIONS

55-3800-1 Rev. B • 1/2014

PRECAUTIONS PRECAUTIONS

NEVER FREE-REV THE MOTOR Free-running your brushless

motor in a no-load condition can result in rotor failure and ESC

transistor damage & will void the product’s warranty!

Never free-rev your system to “see how it runs” or you may not get to drive it again!

• WATER & ELECTRONICS DON’T MIX Never allow water, moisture, or other foreign materials to get inside motor, or on PCBs.

• NOVAK MOTORS & ESCs FOR BEST RESULTS Use Novak sensored motors with Novak Brushless ESCs for best performance & protection. use motors with the proper number of turns to match ESC’s rating.

Use of this brushless motor with ESCs that advance motor

timing can result in excessive current draw & severe motor

damage that will NOT be covered by the product’s warranty!

• DO NOT use Ballistic8 motors above 50,000 RPM.

• INSULATE EXPOSED WIRES Use heat shrink tubing to prevent shorts.

• NO SOLVENTS Do NOT expose the motor to any type of solvents.

• SET GEAR MESH PROPERLY Too tight of a gear mesh can result in

motor pinion shaft breakage--be sure to adjust mesh properly.

Only

closed design will keep most dirt & debris out, but some will get in and eventually cause wear. If the shaft does not spin freely, you may need bearing replacement

from Novak) help extend bearing life--however, too much oil will attract dirt and will cause problems, so apply sparingly.

• CLEAN INSIDE MOTOR periodically by removing front end cap, removing the rotor, and blowing out the inside of the motor with compressed air. Be sure not to lose any small shim washers that may be

on the ends of the rotor shaft & keep them in the correct location.

. A small drop of light oil on the bearings periodically can

(replacement bearing accessory kits are available

SENSOR HARNESS WIRING SENSOR HARNESS WIRING

Should any of the small Teﬂon wires pull out of the motor’s sensor harness connector, re-insert them in the connector’s appropriate slot as shown below. There is a small plastic tab that grabs a small raised barb on the back of the metal socket crimped onto the Teﬂon wire’s end. Check the plastic tab to make sure it has not deformed excessively before inserting the socket into the plastic connector housing with the barb toward the plastic tabs.

Note: Remove or loosen the bearing cap to remove or insert a sensor harness.

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orange

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red

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raised metal

barb

BALLISTIC

BRUSHLESS MOTOR INSTRUCTIONS

NEVER FREE-REV THE MOTOR Free-running your brushless

motor in a no-load condition can result in rotor failure and ESC

transistor damage & will void the product’s warranty!

Never free-rev your system to “see how it runs” or you may not get to drive it again!

• WATER & ELECTRONICS DON’T MIX Never allow water, moisture, or other foreign materials to get inside motor, or on PCBs.

• NOVAK MOTORS & ESCs FOR BEST RESULTS Use Novak sensored motors with Novak Brushless ESCs for best performance & protection. use motors with the proper number of turns to match ESC’s rating.

Use of this brushless motor with ESCs that advance motor

timing can result in excessive current draw & severe motor

damage that will NOT be covered by the product’s warranty!

• DO NOT use Ballistic8 motors above 50,000 RPM.

• INSULATE EXPOSED WIRES Use heat shrink tubing to prevent shorts.

• NO SOLVENTS Do NOT expose the motor to any type of solvents.

• SET GEAR MESH PROPERLY Too tight of a gear mesh can result in

motor pinion shaft breakage--be sure to adjust mesh properly.

55-3800-1 Rev. B • 1/2014

Only

• CHECK ALL MOTOR SCREWS for loosening at regular intervals, just like other hardware on your vehicle. Note: The 3 main socket head screws

that hold the motor together may require tightening after a few runs of the motor. Also check the 3 ﬂat head screws securing the end cap on

the back of the motor--DO NOT OVER-TIGHTEN THESE SCREWS.

• CHECK MOTOR BEARING WEAR after extensive use. The motor’s closed design will keep most dirt & debris out, but some will get in and eventually cause wear. If the shaft does not spin freely, you may need bearing replacement

from Novak) help extend bearing life--however, too much oil will attract dirt and will cause problems, so apply sparingly.

• CLEAN INSIDE MOTOR periodically by removing front end cap, removing the rotor, and blowing out the inside of the motor with compressed air. Be sure not to lose any small shim washers that may be

on the ends of the rotor shaft & keep them in the correct location.

. A small drop of light oil on the bearings periodically can

(replacement bearing accessory kits are available

Note: Remove or loosen the bearing cap to remove or insert a sensor harness.

black

orange

white

red

blue

green

raised metal

barb

ACCESSORIES ACCESSORIES

51XX

(5100-5123) 5mm Mod-1 Steel Pinion Gears--9T to 20T--Hardened steel, 5mm bore.

51XX

(5152-5161) 5mm 32-Pitch Steel Pinion Gears--12T to 17T--Hardened steel, 5mm bore. 5351 Brushless Shielded Sensor Harness--4”--Double-ended motor sensor harness. 5352 Brushless Shielded Sensor Harness--6”--Double-ended motor sensor harness. 5353 Brushless Shielded Sensor Harness--9”--Double-ended motor sensor harness. 5508 14GA Brushless Wire Set--2 pieces each of 9” silicone blue, yellow, orange, black & red. 5512 12GA Super-Flex Wire--Black, Red, & Blue--3 ft each color, silicone. 5514 14GA Super-Flex Wire--Black, Red, & Blue--3 ft each color, silicone. 5644 Black Cooling Fan: 40mm x 40mm x 10mm--2-pin JST connector, 5.7CFM @ 5VDC. 5731 3.5mm Power Connectors--5 pair--Gold plated low-loss connectors for 12-14G wire. 5741 4mm Power Connectors--5 pair--Gold plated low-loss high-amp 12-14G connectors. 5832 Lead-Free 3% Silver Racing Solder--15g--Low-resistance, high-conductivity solder. 5850 Heat Shrink Tubing Assortment--6pc--6” long tubing in six sizes from 1/16”-3/8”. 5851 Heat Shrink Tubing Assortment--24pc--6” long tubing in six sizes from 1/16”-3/8”. 5980 Ballistic 8 Sintered Rotor--Replacement 16mm 4-pole Kevlar-wrapped/epoxied rotor. 5981 Ballistic 8L Sintered Rotor--Replacement 16mm 4-pole Kevlar-wrapped/epoxied rotor. 5982 Ballistic 8/8L Front & Rear Flanged Bearing Set--Replacement bearing set. 5983

Ballistic 8/8L Back End Cap/Bearing 5984 Ballistic 8/8L Timing Assembly--Replacement timing & sensor section of Ballistic 8/8L. 5985 Ballistic 8 Outer Sleeve/Heat Sink--Replacement outer sleeve for Ballistic 8. 5986 Ballistic 8L Outer Sleeve/Heat Sink--Replacement outer sleeve for Ballistic 8L. 5987 Ballistic 8/8L Front End Cap/Back Ring--Front end cap (w/bearing) & back end ring. 5988 Ballistic 8 Motor Hardware Set--Replacement screws & shims for Ballistic 8 motor. 5989 Ballistic 8L Motor Hardware Set--Replacement screws & shims for Ballistic 8L motor. 6801 Ballistic 8 Hand-Wound Stator--Y1.5T--Ballistic 8 Wye-wound 1.5-turn stator. 6802 Ballistic 8 Hand-Wound Stator--D2.0T--Ballistic 8 Delta-wound 2.0-turn stator.

--Replacement back end cap w/bearing factory-installed.

Novak Electronics, Inc.

19 Rancho Circle

Lake Forest, CA 92630

(949) 833-8873 • Monday-Thursday

Customer Service e-mail: cs@teamnovak.com

www.tea m n o v a k . c o m

plastic

tabs

metal barbs

metal socket on end of

Teﬂon sensor harness wires

SERVICE PROCEDURES

Consider changing out motor parts yourself. All of the Ballistic 8/8L’s main components are available as service items--Refer to ‘Accessories’ section or check out our web site. In

most cases, replacing motor parts is less expensive than sending in your motor for service. After reviewing instructions, tech section and how-to video section of website, if you feel your motor requires service the most current product service options & pricing by one of the following methods: WEB: Print out the product SERVICE FORM from CUSTOMER SERVICE section of the web site. Fill out required information on form & return it with the product requiring service. PHONE/FAX/E-MAIL: Contact our customer service department by phone, fax, or e-mail, and we will supply you with current service options. WARRANTY SERVICE: You MUST CLAIM WARRANTY on product PRODUCT SERVICE FORM & include a valid cash register receipt with purchase date, dealer name, & phone # on it, or a previous service invoice. If warranty provisions have been voided, there will be service charges.

ADDITIONAL NOTES:

•

Dealers/distributors are not authorized to replace products thought to be defective.

•

If a hobby dealer returns your product for service, submit a completed product SERVICE

FORM to dealer & make sure it’s included with items.

PRODUCT WARRANTY

Novak Brushless motors are guaranteed to be free from defects in materials or workmanship for a period of 120 days from the original date of purchase (veriﬁed by dated, itemized sales receipt). Warranty does not cover incor- rect installation, components worn by use, cross-connection of battery/motor power wires, overheating solder tabs, damage resulting from thermal overload or operation above 175°F, use of excessive timing or overheating, splices or damage to the sensor harness, damage from disassembling motor, tampering with internal electronics, allowing water, moisture, or any other foreign material to enter motor or get onto the PC board, short-circuiting of motor by allowing exposed wiring or solder tabs to cross-connect or ESC applying simultaneous power to more than one phase at a time from switching to Brush Mode, free-revving motor, or any damage caused by a crash, ﬂooding, or natural disaster. In no case shall our liability exceed the product’s original cost. We reserve the right to modify warranty provisions without notice. Because Novak R/C, Inc. has no control over the connection & use of motor or other related electronics, no liability may be assumed nor will be accepted for damage resulting from the use of this product. Every motor is thoroughly tested and cycled before leaving our facility and is, therefore, considered operational. This product is not a toy, and is not intended for use by children under 14 years of age without the strict supervision of an adult. Use of this product in a uncontrolled manner may result in physical damage or injuries. Take extra care when operating any remote control vehicle. By the act of connecting/operating speed control, the user accepts all resulting liability.

No part of these instructions may be reproduced without the written permission of Novak R/C, Inc. ©Novak R/C, Inc. California, U.S.A. All Rights Reserved. Novak motors are proudly designed in the U.S.A.

(motor may appear to have failed when other problems exist)

, obtain

51XX

(5100-5123) 5mm Mod-1 Steel Pinion Gears--9T to 20T--Hardened steel, 5mm bore.

51XX

Novak Electronics, Inc.

Lake Forest, CA 92630

(949) 833-8873 • Monday-Thursday

Customer Service e-mail: cs@teamnovak.com

www.tea m n o v a k . c o m

--Replacement back end cap w/bearing factory-installed.

19 Rancho Circle

plastic

tabs

metal barbs

metal socket on end of

Teﬂon sensor harness wires

SERVICE PROCEDURES

Consider changing out motor parts yourself. All of the Ballistic 8/8L’s main components are available as service items--Refer to ‘Accessories’ section or check out our web site. In

ADDITIONAL NOTES:

•

Dealers/distributors are not authorized to replace products thought to be defective.

•

If a hobby dealer returns your product for service, submit a completed product SERVICE

FORM to dealer & make sure it’s included with items.

PRODUCT WARRANTY

(motor may appear to have failed when other problems exist)

, obtain

INSTALLATION INSTRUCTIONS INSTALLATION INSTRUCTIONS

1. NO MOTOR CAPACITORS & SCHOTTKY NEEDED

Novak brushless motors do not need motor capacitors or external

Schottky diodes--

2. CHECK MOTOR SCREW LENGTH & INSTALL MOTOR

•

Insert the motor mounting screws that came with your vehicle through the motor mounting plate. Ballistic8 motors need no

more than about 3/16” of screw extending past the vehicle’s

Schottky diode usage will damage ESC

TIMING WARNING (Important

Due to the nature of timing advance speed controls, motor tolerances & settings, vehicle performance, and track conditions, it has become virtually impossible to provide installation and operation recommendations that will allow you to use these speed controls and motors at their highest performance levels without the potential for unwanted damage.

You must, use extreme caution when setting up these electronics and carefully test your application to avoid overloading and overheating either the speed control or the motor. These are racing electronics used in racing conditions, and therefore damage as the result of excessive overheating will not be covered under the product’s factory warranty.

mounting plate (4-5mm)--Too little can strip the motor’s threads,

too much will cause internal motor damage & will void warranty.

• Attach motor to vehicle’s motor mount using one of the sets of threaded mounting holes--select a mounting position that keeps the

solder tabs clear of conductive surfaces like aluminum or graphite.

INSTALL PINION GEAR (see GEAR SELECTION)

Install pinion on motor and test ﬁt in vehicle to align pinion and

spur gears. Tighten pinion’s set screw on the ﬂat of motor shaft.

4. ADJUST MOTOR FOR PROPER GEAR MESH

•

Adjust the motor position for proper amount of free play. You

NEED to have a small amount of play between the pinion gear and the spur gear

(about the thickness of piece of paper)--check

the free play at several positions around the spur gear to ensure a proper mesh

MAKE SURE THE PINION/SPUR GEAR MESH IS NOT TOO TIGHT!

(just in case the gears are out of round).

If gear mesh is too tight, motor shaft breakage can occur.

• Tighten motor mounting screws--Avoid using excessive force, as the threaded holes in motor could become stripped.

5. SOLDER MOTOR POWER WIRES

(skip this step if motor is wired to ESC)

• Determine the best routing in vehicle for the motor’s silicone power wires--avoid any moving parts & suspension.

GEAR SELECTION (Important

Motor operating temperature is the ONLY

way to properly set the maximum vehicle gearing

The motor should be 160-175°F MAX at end of run!

Temperatures above 175°F will weaken the magnet & may

melt the coils! This voids warranty & can damage ESC!

Change the gearing to avoid overheating.

Because of potential ESC/Motor overheating, damage, & failure, you must start with VERY small pinion sizes and check ESC & motor temperatures multiple

times during initial runs to ensure that you are not causing excessive heating.

If ESC/Motor temperatures remain low & stable, you can slowly increase the pinion size while again monitoring the temperatures to determine safe gearing for your vehicle, motor, & track conditions. Because these variables can change, you MUST continually

monitor ESC & motor temperatures to protect your electronics from damage.

Because of the broad power band of brushless, you can go 1-2 teeth higher

pinion than the above recommendations for more top speed, but remember any

See our website or contact us for additional gearing information & recommendations.

higher will produce excessive ESC & motor heating.

• Prepare ends of power wires by stripping 3/16-1/4” of insulation from end of wire. Tin wire ends with solder.

• Lay tinned end of the wire ﬂat on the proper solder tab

(refer to phase markings on end ring above solder tabs)

and solder

wires to the motor. Apply heat with a high-power soldering

iron to the power wire and solder tab--begin adding solder to tip of iron and to wire--Add just enough solder to form a clean

& continuous joint from the solder tab up onto the wire.

WARNING: Be sure no phase wires make contact with an adjacent solder tab--this will cause short-circuiting, damage electronics, & void warranty.

IMPORTANT NOTE: DO NOT OVERHEAT SOLDER TABS

Prolonged/excessive heating will damage tabs & void the warranty.

6. CONNECT MOTOR SENSOR HARNESS

• Determine the best routing in vehicle for the motor’s sensor harness--securing sensor harness to the motor power wires with a tie-wrap can provide a good location & also act as a strain relief.

• Connect one end of sensor harness to ESC & the other end

to the motor’s sensor harness connector located under the back bearing cover--remove two ﬂat head screws to remove

cover to access connector. Be sure the plug on the ends of the harness insert all the way into the sensor harness connectors--the plug & connector are keyed and will only go together one direction.

MOTOR TIMING ADJUSTMENT MOTOR TIMING ADJUSTMENT

The Ballistic 8/8L motor’s timing is adjustable by simply loosening the three M2.5 ﬂat head screws on the back bearing cap, rotating the bearing cap to desired setting, and then re-tightening the screws.

The motor’s factory timing is marked with a timing label located on the side of the back bearing cap and lines up with a groove milled into the top of the back end ring. Novak motors are factory timed to the most efﬁcient setting for their given wind.

Note: Wye-wound motors are timed to the “Y” mark on the motor’s timing label and Delta-wound motors are timed to the “D” mark on the label. When replacing a stator with a different wind type (Wye/Delta) rotate the end cap to line up with the appropriate wind type for proper motor operation.

Advancing the timing will increase the motor’s RPM range & reduce its torque, but will also make the motor less efﬁcient and it will in turn pull more current, resulting in higher speed control & motor operating temperatures.

Adjusting the timing more than 2 timing marks on the timing label

will result in dangerously high current draw and heating that can lead

to ESC & motor failure, and will void the product’s warranty.

Retarding the timing will reduce the motor’s RPM range & increase its torque--this also usually reduces current draw and lowers operating temperatures. For each timing mark (on label) reduced, you should increase the pinion gear size by one tooth to accommodate for the lower RPM range.

)

1. NO MOTOR CAPACITORS & SCHOTTKY NEEDED

Novak brushless motors do not need motor capacitors or external

Schottky diodes--

2. CHECK MOTOR SCREW LENGTH & INSTALL MOTOR

•

Insert the motor mounting screws that came with your vehicle through the motor mounting plate. Ballistic8 motors need no

more than about 3/16” of screw extending past the vehicle’s mounting plate (4-5mm)--Too little can strip the motor’s threads,

too much will cause internal motor damage & will void warranty.

)

• Attach motor to vehicle’s motor mount using one of the sets of threaded mounting holes--select a mounting position that keeps the

solder tabs clear of conductive surfaces like aluminum or graphite.

INSTALL PINION GEAR (see GEAR SELECTION)

Install pinion on motor and test ﬁt in vehicle to align pinion and

spur gears. Tighten pinion’s set screw on the ﬂat of motor shaft.

4. ADJUST MOTOR FOR PROPER GEAR MESH

•

Adjust the motor position for proper amount of free play. You

NEED to have a small amount of play between the pinion gear and the spur gear

the free play at several positions around the spur gear to ensure a proper mesh

MAKE SURE THE PINION/SPUR GEAR MESH IS NOT TOO TIGHT!

If gear mesh is too tight, motor shaft breakage can occur.

• Tighten motor mounting screws--Avoid using excessive force, as the threaded holes in motor could become stripped.

5. SOLDER MOTOR POWER WIRES

• Determine the best routing in vehicle for the motor’s silicone power wires--avoid any moving parts & suspension.

• Prepare ends of power wires by stripping 3/16-1/4” of insulation from end of wire. Tin wire ends with solder.

• Lay tinned end of the wire ﬂat on the proper solder tab

(refer to phase markings on end ring above solder tabs)

wires to the motor. Apply heat with a high-power soldering iron to the power wire and solder tab--begin adding solder to tip of iron and to wire--Add just enough solder to form a clean

& continuous joint from the solder tab up onto the wire.

WARNING: Be sure no phase wires make contact with an adjacent solder tab--this will cause short-circuiting, damage electronics, & void warranty.

IMPORTANT NOTE: DO NOT OVERHEAT SOLDER TABS

Prolonged/excessive heating will damage tabs & void the warranty.

6. CONNECT MOTOR SENSOR HARNESS

• Determine the best routing in vehicle for the motor’s sensor harness--securing sensor harness to the motor power wires with a tie-wrap can provide a good location & also act as a strain relief.

• Connect one end of sensor harness to ESC & the other end

to the motor’s sensor harness connector located under the back bearing cover--remove two ﬂat head screws to remove

cover to access connector. Be sure the plug on the ends of the harness insert all the way into the sensor harness connectors--the plug & connector are keyed and will only go together one direction.

Schottky diode usage will damage ESC

(about the thickness of piece of paper)--check

(just in case the gears are out of round).

(skip this step if motor is wired to ESC)

and solder

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BALLISTIC 8/8L MOTOR

Exploded View

4-40 socket

head cap screws

ﬁberglass

front insulator

front end cap front end cap

drill balanced

Kevlar-wrapped

4-pole rotor

outer sleeve/heat sink outer sleeve/heat sink

low-loss solder tabs low-loss solder tabs

epoxy-dipped

hand-wound

12 slot stator

ﬁberglass stamping insulators

timing

assembly

sensor harness

connector

bearing

back

end ring

available replacement components.

cap

timing groove timing groove

Refer to ‘Accessories’ section for

cover

M2.5x10mm

ﬂat head

cap screws