NOVAK BALLISTIC BRUSHLESS - MOTOR INSTRUCTIONS REV D Instructions

BALLISTIC BRUSHLESS
MOTOR INSTRUCTIONS
55-3600-1 Rev. D
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. Only
use motors with the proper number of turns to match ESC's rating.
Use of this brushless motor with non-Novak ESCs and 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 Ballistic 550 4.5T-5.5T motors above a 3S Li-Po pack.
• DO NOT use 3.5-7.5T motors with Havoc 2S, Havoc 3S 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.
ACCESSORIES
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.
S5425 550-Size Novak Brushless Motor Sleeve--Black--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.
5832 Lead-Free 3% Silver Racing Solder--15g--Low-resistance, high-conductivity solder.
S5903 Ballistic Motor Insulator Pack--Replacement paper disk, fiberglass cover & silicone grommet
5909 Sintered 13mm Tuning Rotor--High-power sintered neodymium tuning rotor.
5936 Ceramic Ball Bearing ABEC-5--Replacement oversized, front ceramic bearing
5938 Steel Ball Bearings ABEC-5--Replacement oversized, front steel bearing kit
S5932 Ballistic Motor Hardware Kit--Replacement motor screws & shim washers.
S5933 Ballistic 550 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 steel bearing.
S5944 Ballistic Back End Bell--Replacement back end bell of motor. Black anodized/Ribbed.
S5945 Ballistic Crawler Timing/Sensor Assembly--Replacement timing & sensor section of crawler motor.
S5946 Ballistic Bearing Cap/Back Bearing--Replacement bearing cap/Factory-installed ceramic bearing.
5947 Ballistic 550 Front End Bell & Bearing--Black anodized/Ribbed/Factory-installed bearing.
5948 Ballistic 550 Rotor --Replacement 12.3mm high-power sintered neodymium rotor.
5949 Ballistic 550 Tuning Rotor --14mm high-power sintered neodymium tuning rotor.
5950 Crawler Sintered Tuning Rotor--14mm high-power sintered neodymium tuning rotor.
S6504 Ballistic 550 Hand-Wound Stator--4.5T--Interchangeable Ballistic 550 4.5-turn stator.
S6505 Ballistic 550 Hand-Wound Stator--5.5T--Interchangeable Ballistic 550 5.5-turn stator.
S6506 Ballistic 550 Hand-Wound Stator--6.5T--Interchangeable Ballistic 550 6.5-turn stator.
S6507 Ballistic 550 Hand-Wound Stator--7.5T--Interchangeable Ballistic 550 7.5-turn stator.
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.
S6609 Ballistic Hand-Wound Stator--9.5T--Interchangeable Ballistic 9.5-turn stator.
S6610 Ballistic Hand-Wound Stator--10.5T--Interchangeable Ballistic 10.5-turn stator.
S6611 Ballistic Hand-Wound Stator--11.5T--Interchangeable Ballistic 11.5-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.
S6618 Ballistic Hand-Wound Stator--18.5T--Interchangeable Ballistic 18.5-turn stator.
S6621 Ballistic Hand-Wound Stator--21.5T--Interchangeable Ballistic 21.5-turn stator.
S6625 Ballistic Hand-Wound Stator--25.5T--Interchangeable Ballistic 25.5-turn stator.
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.
SENSOR HARNESS WIRING
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.
Note: Remove or loosen the bearing cap to remove or insert a sensor harness.
red
black raised
metal
blue
orange
barb
green
white
plastic
metal metal socket on end of
tabs
barbs Teflon sensor harness wires
SERVICE PROCEDURES
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. 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 (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
previous service work. 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 incorrect instal-
lation, 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 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: cs@teamnovak.com • (949) 833-8873 • FAX (949) 833-1631
©Novak Electronics, Inc. Irvine, CA, U.S.A. • Printed 5/2010
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.
BALLISTIC BRUSHLESS
MOTOR INSTRUCTIONS
55-3600-1 Rev. D
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. Only
use motors with the proper number of turns to match ESC's rating.
Use of this brushless motor with non-Novak ESCs and 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 Ballistic 550 4.5T-5.5T motors above a 3S Li-Po pack.
• DO NOT use 3.5-7.5T motors with Havoc 2S, Havoc 3S 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.
ACCESSORIES
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.
S5425 550-Size Novak Brushless Motor Sleeve--Black--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.
5832 Lead-Free 3% Silver Racing Solder--15g--Low-resistance, high-conductivity solder.
S5903 Ballistic Motor Insulator Pack--Replacement paper disk, fiberglass cover & silicone grommet
5909 Sintered 13mm Tuning Rotor--High-power sintered neodymium tuning rotor.
5936 Ceramic Ball Bearing ABEC-5--Replacement oversized, front ceramic bearing
5938 Steel Ball Bearings ABEC-5--Replacement oversized, front steel bearing kit
S5932 Ballistic Motor Hardware Kit--Replacement motor screws & shim washers.
S5933 Ballistic 550 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 steel bearing.
S5944 Ballistic Back End Bell--Replacement back end bell of motor. Black anodized/Ribbed.
S5945 Ballistic Crawler Timing/Sensor Assembly--Replacement timing & sensor section of crawler motor.
S5946 Ballistic Bearing Cap/Back Bearing--Replacement bearing cap/Factory-installed ceramic bearing.
5947 Ballistic 550 Front End Bell & Bearing--Black anodized/Ribbed/Factory-installed bearing.
5948 Ballistic 550 Rotor --Replacement 12.3mm high-power sintered neodymium rotor.
5949 Ballistic 550 Tuning Rotor --14mm high-power sintered neodymium tuning rotor.
5950 Crawler Sintered Tuning Rotor--14mm high-power sintered neodymium tuning rotor.
S6504 Ballistic 550 Hand-Wound Stator--4.5T--Interchangeable Ballistic 550 4.5-turn stator.
S6505 Ballistic 550 Hand-Wound Stator--5.5T--Interchangeable Ballistic 550 5.5-turn stator.
S6506 Ballistic 550 Hand-Wound Stator--6.5T--Interchangeable Ballistic 550 6.5-turn stator.
S6507 Ballistic 550 Hand-Wound Stator--7.5T--Interchangeable Ballistic 550 7.5-turn stator.
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.
S6609 Ballistic Hand-Wound Stator--9.5T--Interchangeable Ballistic 9.5-turn stator.
S6610 Ballistic Hand-Wound Stator--10.5T--Interchangeable Ballistic 10.5-turn stator.
S6611 Ballistic Hand-Wound Stator--11.5T--Interchangeable Ballistic 11.5-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.
S6618 Ballistic Hand-Wound Stator--18.5T--Interchangeable Ballistic 18.5-turn stator.
S6621 Ballistic Hand-Wound Stator--21.5T--Interchangeable Ballistic 21.5-turn stator.
S6625 Ballistic Hand-Wound Stator--25.5T--Interchangeable Ballistic 25.5-turn stator.
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.
SENSOR HARNESS WIRING
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.
Note: Remove or loosen the bearing cap to remove or insert a sensor harness.
red
black raised
metal
blue
orange
barb
green
white
plastic
metal metal socket on end of
tabs
barbs Teflon sensor harness wires
SERVICE PROCEDURES
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. 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 (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
previous service work. 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 incorrect instal-
lation, 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 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: cs@teamnovak.com • (949) 833-8873 • FAX (949) 833-1631
©Novak Electronics, Inc. Irvine, CA, U.S.A. • Printed 5/2010
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.