MOTOR TIMING ADJUSTMENT
• Rotor Position Knowledge
--With ESC & motor continuously synchronized
via the motor harness, the sensor-based system provides instantaneous
throttle response & smooth neutral to drive transitions--
NO COGGING
.
• Smooth/Controlled Low Speed Driveability
--Rotor position knowledge
is key to smooth acceleration--no abrupt/uncontrolled bursts of power.
• Strong/Consistent Brakes & Starting Torque
--Rotor position
knowledge results in consistent starts & stops, no lag time or hesitation
before acceleration or braking--this translates to consistent lap times.
• Locked Rotor & Thermal Protection
--Position & temperature sensors
inside the motor provide unparalleled protection when used with Novak
brushless ESCs, letting you to run pack after pack without worrying
about overheating the motor, ESC, or magnets when properly set-up.
SENSOR-BASED DESIGN BENEFITS
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.
• CHECK MOTOR SCREWS
Remember to check all motor screws for
loosening after a few runs of the motor.
• NOVAK MOTORS & ESCs FOR BEST RESULTS
Use Novak sensored
motors with Novak Brushless ESCs for best performance & protection. Only
use motors with the proper number of turns to match ESC’s rating.
Use of this brushless motor with non-Novak 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 3.5-7.5T motors with Havoc, XBR, Super Sport, or Mongoose ESCs.
• 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.
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.
• 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
(replacement bearing accessory kits are available
from Novak)
. A small drop of light oil on the bearings periodically can
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 bell,
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.
SERVICE PROCEDURES
After reviewing instructions & tech section of website, if you feel your motor requires
service
(motor may appear to have failed when other problems exist)
, obtain the most
current product service options & pricing by one of the following methods:
WEBSITE:
Print a copy of the product
SERVICE FORM
from the SERVICE section of the
Novak website. Fill out the needed information & return it with the Novak product.
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
SERVICE FORM
& include
a valid, itemized cash register receipt with the purchase date on it, or an invoice from previ-
ous service work.
If warranty provisions have been voided, there will be service charges.
ADDITIONAL NOTES:
• Consider changing out motor parts yourself.
All of the Ballistic’s main components are
available as service items
--Refer to ‘Accessories’ section or check out our website.
• 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
incorrect 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 failure
from using non-Novak ESCs that advance motor timing, 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
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 act of God. In no case shall our liability
exceed the product’s original cost. We reserve the right to modify warranty provisions without notice.
Because Novak Electronics, 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.
e-mail:
• (949) 833-8873 • FAX (949) 833-1631
©Novak Electronics, Inc. Irvine, CA, U.S.A. • Printed 7/2009
No part of these instructions may be reproduced without the written permission of Novak Electronics, Inc.
All Rights Reserved. Novak motors are proudly designed in the U.S.A.
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.
5413 Heat Sink Motor Sleeve--Black
--Replaces Novak 540 motor sleeve.
5414 Heat Sink Motor Sleeve--Purple
--Replaces Novak 540 motor sleeve.
5415 Heat Sink Motor Sleeve--Blue
--Replaces Novak 540 motor sleeve.
5416 540 Novak Brushless Motor Cooling Kit--Black
--Heat sink sleeve & 25mm fan.
5417 540 Novak Brushless Motor Cooling Kit--Purple
--Heat sink sleeve & 25mm fan.
5418 540 Novak Brushless Motor Cooling Kit--Blue
--Heat sink sleeve & 25mm fan.
S5420 540-Size Novak Brushless Motor Sleeve--Black
--Novak replacement sleeve.
S5421 540-Size Novak Brushless Motor Sleeve--Blue
--Novak replacement sleeve.
S5422 540-Size Novak Brushless Motor Sleeve--Gold
--Novak replacement sleeve.
S5423 540-Size Novak Brushless Motor Sleeve--Purple
--Novak replacement sleeve.
S5424 540-Size Novak Brushless Motor Sleeve--Orange
--Novak replacement sleeve.
5508 14GA Brushless Wire Set
--2 pieces each of 9” silicone blue, yellow, orange, black, & red.
5509 16GA 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.
5647 Black Cooling Fan--25x25x10mm
--All purpose cooling fan with 2-pin JST connector.
5648 Clear Cooling Fan--30x30x6mm
--GTB replacement fan with 2-pin JST connector.
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.
5810 Gold Battery Cross Bars--7pcs
--Gold plated oxygen-free copper battery bars.
5811 Gold Battery Cross Bars--28pcs
--Gold plated oxygen-free copper battery bars.
5820 Silver Battery Cross Bars--7pcs
--Oxygen-free copper battery bars, plated for easy soldering.
5821 Silver Battery Cross Bars--28pcs
--Oxygen-free copper battery bars, plated for easy soldering.
5831 Lead-Free 3% Silver Racing Solder--6g
--Low-resistance, high-conductivity solder.
5832 Lead-Free 3% Silver Racing Solder--15g
--Low-resistance, high-conductivity solder.
5840 Double-Sided Mounting Tape--10pcs
--1”x1” high-performance clear mounting tape.
5909 Sintered 13mm Tuning Rotor
--High-power sintered neodymium tuning rotor.
S5932 Ballistic Motor Hardware Kit
--Replacement motor screws & shim washers.
5940 Ballistic Front End Bell & Bearing
--Black anodized/Ribbed/Factory-installed bearing.
5941 Sintered 12.3mm Ballistic Rotor
--Replacement Ballistic sintered neodymium rotor.
S5942 Ballistic Timing/Sensor Assembly
--Replacement timing & sensor section of motor.
S5943 Ballistic Bearing Cap & Back Bearing
--Replacement bearing cap/Factory-installed bearing.
S5944 Ballistic Back End Bell
--Replacement back end bell of motor. Black anodized/Ribbed.
S6603 Ballistic Hand-Wound Stator--3.5T
--Interchangeable Ballistic 3.5-turn stator.
S6604 Ballistic Hand-Wound Stator--4.5T
--Interchangeable Ballistic 4.5-turn stator.
S6605 Ballistic Hand-Wound Stator--5.5T
--Interchangeable Ballistic 5.5-turn stator.
S6606 Ballistic Hand-Wound Stator--6.5T
--Interchangeable Ballistic 6.5-turn stator.
S6607 Ballistic Hand-Wound Stator--7.5T
--Interchangeable Ballistic 7.5-turn stator.
S6608 Ballistic Hand-Wound Stator--8.5T
--Interchangeable Ballistic 8.5-turn stator.
S6610 Ballistic Hand-Wound Stator--10.5T
--Interchangeable Ballistic 10.5-turn stator.
S6613 Ballistic Hand-Wound Stator--13.5T
--Interchangeable Ballistic 13.5-turn stator.
S6617 Ballistic Hand-Wound Stator--17.5T
--Interchangeable Ballistic 17.5-turn stator.
S6621 Ballistic Hand-Wound Stator--21.5T
--Interchangeable Ballistic 21.5-turn stator.
ACCESSORIES
BALLISTIC BRUSHLESS
MOTOR INSTRUCTIONS
55-3600-1 Rev. B
black
orange
white
plastic
tabs
red
blue
green
metal
barbs
raised
metal
barb
metal socket on end of
Teflon sensor harness wires
Should any of the 26G 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.
SENSOR HARNESS WIRING
1.
NO MOTOR CAPACITORS & SCHOTTKY NEEDED
Novak brushless motors do not need motor capacitors or external
Schottky diodes--
Schottky diode usage will damage ESC
.
2. CHECK MOTOR SCREW LENGTH & INSTALL MOTOR
• Insert the motor mounting screws that came with your vehicle
through the motor mounting plate.
540-size motors need no
more than 1/8” of screw extending past the vehicle’s mounting
plate (2-4mm)--
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
.
3. INSTALL PINION GEAR
(see GEAR SELECTION on back)
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
(just in case the gears are out of round)
.
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 1/8-1/4” of
insulation from end of wire. Tin wire ends with solder.
•
Lay tinned end of the wire flat on the solder tab and solder
wires to proper tabs of the motor
(refer to phase markings
below solder tabs)
. Apply heat with 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 wire strands have strayed to an adjacent solder tab--this
will cause short-circuiting, damage electronics, & void product’s warranty.
IMPORTANT NOTE:
DO NOT OVERHEAT SOLDER TABS
Prolonged or excessive heating of the solder tabs will
cause damage & void the product’s 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 the harness to the ESC & the other end
to the motor’s sensor harness connector located under the
back bearing cap
. Be sure the plug on the end of the harness
inserts all the way into the sensor harness connector--
the plug
& connector are keyed and will only go together one direction
.
INSTALLATION INSTRUCTIONS
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.
Gearing Starting Points for 6-Cell (2S Li-Po) Use:
The gearing recommendations below are given in Final Drive Ratio* and Rollout**.
For more information on how to determine proper gearing, visit the Novak website.
If you do not change gearing after switching to brushless, you will be over-
geared and will have slow acceleration & excessive temperatures!
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 higher will produce excessive
ESC & motor heating. Check motor’s operating temperature after making gearing adjustments.
See our website for additional gearing recommendations, final drive
ratios, or if your motor does not appear above.
GEAR SELECTION
(Important)
outer sleeve
hand-wound
stator
low-loss solder tabs
timing
assembly
sensor harness
connector
back
end bell
bearing
cap
M2.5 x 10mm
flat head
cap screws
fish paper
insulator
front end bell
fiberglass
stamping
insulator
4-40 x 1.75”
socket head
cap screws
BALLISTIC MOTOR
Exploded View
The Ballistic 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 re-tighten the screws.
The motor’s factory timing is marked with a ‘N’ on the 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 bell. Novak motors are factory timed to the most efficient
setting for their given wind.
Advancing the timing
will increase the motor’s RPM range & reduce its torque,
but will also make it less efficient and it will pull more current, resulting in
higher ESC & motor operating temperatures.
Adjusting the timing beyond the ‘+’ mark 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 torque--
this usually also reduces current draw and lower operating temperatures. For
each timing mark
(on label)
reduced, increase pinion gear size by one tooth
to accommodate lower RPM range.
timing groove
Refer to ‘Accessories’ section for
available replacement components.
w w w . t e a m n o v a k . c o m
Motor Turn
Touring Car*
2wd Buggy*
2wd Truck*
Oval** (4-cell/1S)
3.5T
10.5
Not Rec.
Not. Rec.
1.2”/31mm
4.5T
9.5
Not Rec.
13
1.3”/33mm
5.5T
8.5
11
12.5
1.4”/35mm
6.5T
7.5
10
11.5
1.5”/38mm
7.5T
7
9.5
11
1.6”/40.5mm
8.5T
6.5
9
10.5
1.7”/43mm
10.5T
5.5
8
9.5
2.6”/66mm
13.5T
4.5
7
8.5
2.9”/74mm
17.5T
4.0
6.5
8.0
3.2”/82mm
21.5T
3.75
6.0
7.5
3.50”/89mm
