LZ design FES-DG-M100 User manual

FES MOTOR MANUAL
Version 1.0
Type: FES-DG-M100
This manual is accepted by DG Aviation as manual for the
motor FES-DG-M100, if used in the DG-1001E.
Issued
(DE/EI)
LZ Design
Checked
(CVE/MPI)
Wassenaar
Approved
(HoOA/LMPL)
Dirks
Date
Nov. 2022
Date
16 .Nov. 2022
Date
16. Nov. 2022
LZ design d.o.o., Brod 3D, 1370 Logatec, Slovenia tel [phone]
[email protected] www.front-electric-sustainer.com

Table of Content
1. Important notices..................................................................................................... 3
1.1 Limited Warranty ................................................................................................. 3
2. General.................................................................................................................... 4
3. Model designation .................................................................................................... 4
4. Technical data and limitations of motor ..................................................................... 5
5. Drawing of motor ..................................................................................................... 6
6. Maintenance ............................................................................................................ 7
7. Removal of motor..................................................................................................... 8
8. Installation of motor............................................................................................... 10
9. Repair and service.................................................................................................. 11
10. Revision history.................................................................................................... 11

1. Important notices
Please read this manual thoroughly. It contains important information about your
system, having a vital importance to the flight safety.
Information in this document is subject to change without notice. LZ design reserves
the right to change or improve their products and to make changes in the content of this
material without obligation to notify any person or organization of such changes or
improvements.
The following definitions apply to warnings, cautions and notes used in this manual.
Warning: Means that the non-observation of the corresponding procedure
leads to an immediate or important degradation of the flight safety.
Caution: Means that the non-observation of the corresponding procedure
leads to a minor or to a long-term degradation of the flight safety.
Note: Draws the attention to any special item not directly related to safety
but which is important or unusual.
1.1 Limited Warranty
This motor is warranted to be free from defects in materials or workmanship for two
years from the date of purchase. Within this period, LZ design will, at its sole option,
repair or replace any components that fail in normal use. Such repairs or replacement will
be made at no charge to the customer for parts and labour, the customer shall be
responsible for any transportation cost. This warranty does not cover failures due to
abuse, misuse, accident, or unauthorized alterations or repairs.
THE WARRANTIES AND REMEDIES CONTAINED HEREIN ARE EXCLUSIVE AND IN
LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED OR STATUTORY, INCLUDING
ANY LIABILITY ARISING UNDER ANY WARRANTY OF MERCHANTABILITY OR FITNESS
FOR A PARTICULAR PURPOSE, STATUTORY OR OTHERWISE. THIS WARRANTY GIVES
YOU SPECIFIC LEGAL RIGHTS, WHICH MAY VARY FROM STATE TO STATE.
IN NO EVENT SHALL LZ DESIGN BE LIABLE FOR ANY INCIDENTAL, SPECIAL, INDIRECT
OR CONSEQUENTIAL DAMAGES, WHETHER RESULTING FROM THE USE, MISUSE, OR
INABILITY TO USE THIS PRODUCT OR FROM DEFECTS IN THE PRODUCT. Some states do
not allow the exclusion of incidental or consequential damages, so the above limitations
may not apply to you. LZ design retains the exclusive right to repair or replace the unit or
software, or to offer a full refund of the purchase price, at its sole discretion. SUCH
REMEDY SHALL BE YOUR SOLE AND EXCLUSIVE REMEDY FOR ANY BREACH OF
WARRANTY.
To obtain warranty service, contact your local LZ design dealer or contact LZ design
directly.
2022 © LZ design. All rights reserved.

2. General
Congratulations on your purchase. This is a high-end product of brushless
synchronous permanent magnet motor with electronically controlled commutation system
3 phase, which will keep its capability for a long time if treated the right way.
The drive was developed and very elaborately tested by Ing. Matija Žnidaršič and
Ing. Luka Žnidaršič.
The development objective was to build suitable motor for FES application which
must be light and small enough to fit into sailplane front part of fuselage, but very
powerful providing specific performance at highest efficiency.
This motor allows a gearless drive without the usually essential gear unit which cause
power losses, additional weight, complexity, and maintenances.
Because of the little internal resistance of the motor, very good performances are
achieved in a wide range and at an excellent efficiency.
Though many intensive tests had already been made and though the parts were
produced by modern CNC machines, the drive is still not a real series product.
Some manufacturing processes like windings are made by hand, what makes every drive
of the first series unique.
3. Model designation
Motor model designation is the following:
FES-DG-M100
(1)
(2)
(3)
where:
- (1) motor application
- (2) designed for powered sailplane type, DG-1001E
- (3) approximate motor length in mm
Motor serial-number is identified as number which follows model designation.
sn: XXX
Motor identification numbers are laser engraved into rear Aluminium plate of motor.
NOTE: Motor type FES-DG-M100 is very similar like all other versions of FES-M100
motors. Main difference between is due to shape of front torsional plate, which is adjusted
to different shape of spinner. For this reason, each FES M100 motor have another marking
regarding specific adjustments for different sailplane types.

4. Technical data and limitations of motor
Motor construction is outrunner BLDC brushless synchronous permanent magnet
motor with electronically controlled commutation system 3 phase. Rotor position is
determined by 3 hall sensors and additional 4th hall sensors for automatic propeller
positioning.
This motor can work only in combination with suitable electronic motor controller
which transform DC current from battery packs to 3 phase current which supply motor.
We use controller type which needs hall position sensors in motor, but this motor can
work also with some sensorless controllers.
Electrical motor type FES-DG-M100 technical specifications:
Maximum torque
75Nm
Rpm non loaded
48 rpm/V
Non loaded motor current (at 5600 rpm)
16-18A
Rotor rink diameter
182mm
Motor length
100mm
Motor weight cca.
8,0 kg
Motor efficiency
85-95 %
Maximum allowed temperature
90°C
Minimum allowed starting temperature
-20°C
Power load on motor P (kW) is dependable of propeller diameter, geometry, pitch
and its rotation speed n (RPM-rotation per minute). However, rotation speed of motor is
than dependable on Voltage level supply to motor controller. Higher supply Voltage, higher
rpm!

5. Drawing of motor

6. Maintenance
The motor does not need any maintenance. Opening or disassembling of
the motor would cause a forfeit of warranty claims! It could be also very
dangerous, due to very strong magnets on rotor!
Though, it must be considered that no foreign objects at all can enter the interior of
the drive.
Further, it is necessary to protect the motor from humidity, dirt, paint, glues etc. If
this is ignored, a proper functionality of the motor cannot be guaranteed, and irreparable
damages are possible. In case of damage, ship the drive back to the manufacturer for
repairs. Unintended handling leads to secondary damages.
Keep magnetic memory cards or electronic devices out of the rotor’s close-up range,
because the alternating magnetic field can cause a delete of data. Be also careful with
medical devices (e.g. pacemakers) which are sensitive to alternating magnetic fields.
The small gap between the stator and the magnets of the rotor function-bound has a
thickness of only a few tenth millimetres. Here, the danger of foreign objects accumulating
in this gap exists but can be heard by scratching-sounds. In this case spinner should be
removed and the motor should be blown-out with compressed air. Do not at all simply
keep on using the drive. Be especially aware of cuttings which can almost irremovably
stick to the magnets. In this case, the only thing that helps is a disassembly of the drive
by the manufacturer.

7. Removal of motor
Note: Removal of motor from sailplane is only allowed in case of written
permission from manufacturer otherwise warranty is not valid anymore!
Warning: It is not allowed to fly with removed motor from the sailplane, as
C.G. position change significantly!
On the back side of the motor bulkhead four M8 nuts are visible. They are tightened over
big spacer and rubber silent blocks. Please do not touch them. Right way of removing
motor is to follow next steps.
To remove the motor from the glider (complete with spinner and propeller)
1. From the cockpit side, remove the glass-fibre cover, mounted in the centre of the
motor bulkhead. To accomplish this, remove six countersunk M4 bolts with their
collars. In the centre of the opening a pneumatic tube is connected to the pitot
tube assembly. Carefully remove the tube from the assembly.

2. Remove pitot tube assembly which is fixed on the back side of motor mounting
plate. To do that is necessary to unscrew two M5 bolts on top. Then carefully pull-
out pitot tube assembly.
3. Unlock two spring-locks which hold DB15 cable connector. Carefully unplug
connector from the socket of motor rear wall.
4. Unscrew 3 locknuts from rear motor wall and disconnect 3 power cables. Each cable
is marked with different colour of isolation over the cable shoe (red, blue and
black). Take a photo so that you will know their proper order for assembly.
5. Un-secure six M8 bolts and unscrew them (note that M8 screw located below power
cables has a lower head). To accomplish removal of the screws, support the motor
assembly.
6. Take out motor assembly carefully. Note that centrifugal ventilator on the back side
of the motor has bigger diameter than rotor ring. It is not possible to get motor out
straight, as opening is not wide enough. It is necessary to rotate motor about 30
degrees to one side to get it out. Be careful not to damage spinner, or plastic
covers below spinner.

8. Installation of motor
To install motor back on glider, follow the reverse order of previous chapter.
Take care about additional steps:
1. Below M8 motor fixation bolts, it is recommended to use new brass safely spacers
2. Make sure that power cables are connected in the same order as before (check
your photo for reference). If order is not correct motor might not run at all, it might
run but not achieving proper RPM or it might run in wrong direction. Use only new
M6 all metal locknuts.
3. Make sure that there is at least 3mm of air gap distance between cable shoes and
motor bulkhead and between cable shoes and M8 bolts. Lower left M8 bolt (below
power cables) should have lower head.
4. Carefully plug in DB15 male connector into motor rear wall female connector.
Secure connector on both sides with spring locks.
5. Reinstall the glass-fibre cover, mounted in the centre of the motor bulkhead.
Tighten six countersunk M4 bolts with their collars.
After motor is reinstalled, check that:
Spinner is nicely located in the middle of the fuselage when spinner is in stop
position. This means that surface of the spinner is as much as possible tangent to
the fuselage contour in area of gap between spinner and fuselage.
Gap between spinner and fuselage should be 0,5-1,5mm. Gap should be equal all
around (on top should be the same as on bottom side, on left side should be equal
as on right side).
All bolted connections are assembled correctly and secured properly. Below six M8
bolts which hold motor in place are thin brass safety spacers, which ears needs to
be bend 90 degrees against one of the 6 vertical surfaces of M8 hex head bolts.
Start the motor on a ground and run it for a few seconds to check:
-that motor rotating direction is counter-clockwise (looking in front of the
propeller), and that motor is running smoothly
-that electronic braking of propeller works (above 1500 RPM)
-FCU instrument is functioning properly (check about all functions of the FCU in
its dedicated FCU manual)

9. Repair and service
In case of a fault or damage, please contact manufacturer.
10. Revision history
November 2022
Initial release of manual, v1.0