Novak Ballistic 8 Motor (55-3800-1 Rev. B) - Manual (Page 2)

MOTOR TIMING ADJUSTMENT MOTOR TIMING ADJUSTMENT
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. 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.
3. 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 (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 (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.
• 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.
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. 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.
3. 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 (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 (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.
• 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.
INSTALLATION INSTRUCTIONS INSTALLATION INSTRUCTIONS
GEAR SELECTION (Important) GEAR SELECTION (Important)
outer sleeve/heat sink outer sleeve/heat sink
epoxy-dipped
hand-wound
12 slot stator
epoxy-dipped
hand-wound
12 slot stator
low-loss solder tabs low-loss solder tabs timing
assembly
timing
assembly
sensor harness
connector
sensor harness
connector
back
end ring
back
end ring
bearing
cap
bearing
cap M2.5x10mm
flat head
cap screws
M2.5x10mm
flat head
cap screws
front end cap front end cap
fiberglass
stamping
insulators
fiberglass
stamping
insulators
4-40 socket
head cap screws
4-40 socket
head cap screws
BALLISTIC 8/8L MOTOR
Exploded View
BALLISTIC 8/8L MOTOR
Exploded View
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 tim-
ing mark (on label) reduced, you should increase the pinion gear size by one tooth
to accommodate for the lower RPM range.
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 tim-
ing mark (on label) reduced, you should increase the pinion gear size by one tooth
to accommodate for the lower RPM range.
timing groove timing groove
Refer to ‘Accessories’ section for
available replacement components.
Refer to ‘Accessories’ section for
available replacement components.
w w w . t e a m n o v a k . c o m w w w . t e a m n o v a k . c o m
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
higher will produce excessive ESC & motor heating.
See our website or contact us for additional gearing information & recommendations.
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
higher will produce excessive ESC & motor heating.
See our website or contact us for additional gearing information & recommendations.
TIMING WARNING (Important) 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 installa-
tion 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.
Due to the nature of timing advance speed controls, motor tolerances & settings, vehicle
performance, and track conditions, it has become virtually impossible to provide installa-
tion 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.
drill balanced
Kevlar-wrapped
4-pole rotor
drill balanced
Kevlar-wrapped
4-pole rotor
bearing
cover
bearing
cover fiberglass
front insulator
fiberglass
front insulator