LZ design FES LCD Display User manual

FES MOTOR MANUAL
Version 1.1
Type: FES-DIA-M100
LZ design d.o.o., •Brod 3D, 1370 Logatec, Slovenia •tel [phone]
[email protected] •www.front-electric-sustainer.com

FES-DIA-M100 MOTOR manual Version 1.1 December 2020
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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 ..................................................................................................... 7
6. Maintenance ............................................................................................................ 8
7. Removal of motor..................................................................................................... 9
8. Installation of motor............................................................................................... 11
9. Repair and service.................................................................................................. 12
10. Revision history .................................................................................................... 12

FES-DIA-M100 MOTOR manual Version 1.1 December 2020
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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.
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.

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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-DIA-M100
(1)
(2)
(3)
where:
- (1) motor application
- (2) designed for sailplane model; DIANA 2 FES
- (3) approximate motor length in mm
Motor serial-number is identified as number which follows model designation
sn: XXX
Motor identification numbers are engraved into rear Aluminium plate of motor.
NOTE: Motor type FES-DIA-M100 is identical like others FES-XXX-M100. It is marked
differently due to different shape of torsional plate to be suitable for specific type of
sailplane.

FES-DIA-M100 MOTOR manual Version 1.1 December 2020
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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 sensor for automatic propeller
positioning.
This motor can work only in combination with suitable electronic 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 controllers without usage of hall sensors.
Electrical motor type FES-DIA-M100 power ratings at 116V on motor controller and
loaded with FES-DIA-P1-102 propeller:
Maximum torque
75 Nm
Maximum current
250A
Maximum Voltage
116V
Rpm non loaded
45 rpm/V
Rpm non loaded (at 116V DC on Controller)
5300 rpm
Non loaded motor current (at 5300 rpm)
16-18 A
Rpm loaded with FES-DIA-P1-100 propeller (1m diameter)
4700 rpm
Battery current loaded (4700 rpm, 116V) with FES-DIA-P1-102
Up to 220 A
Rotor rink diameter
182mm
Motor length
100mm
Motor weight cca.
8,0 kg
Motor efficiency
82-95 %
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 available Voltage on controller. Higher Voltage, higher rpm!

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Power Consumption
0; 0
Horizontal flight
Max climb
0
5
10
15
20
25
01000 2000 3000 4000 5000
n (RPM)
P (kw)
Power consumption curve
Rpm versus Power

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5. Drawing of motor

FES-DIA-M100 MOTOR manual Version 1.1 December 2020
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6. Maintenance
The motor does not need any maintenance. There are no periodic
inspections for motor.
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 should be prevented that foreign objects 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.

FES-DIA-M100 MOTOR manual Version 1.1 December 2020
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7. Removal of motor
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 back side of mounting wall are visible four M8 nuts tightened over big
spacer and rubber silen blocks. Please leave them at they are. Proper way of
removing motor is to follow next steps.
To remove the motor from the glider (complete with spinner and propeller)
1. Open ventilation (knob fully forward position)
Above picture is from Discus, however at Diana is similar arrangement
2. Unscrew 6 M4 inbus bolts and remove composite cover from middle of front motor
mounting rib (from cockpit side)

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3. Unlock springs which hold DB15 cable connector and then carefully unplug
connector from motor rear wall.
4. Unscrew 3 self-locking nuts from rear motor wall and disconnect 3 power cables.
Each is marked with different colour of isolation over cable shoe (red, blue and black).
Take a photo so that you will know their proper order for assembly.
5. Unsecure six M8 bolts and unscrew them out. One of M8 bolts which is below
powers wires have lower head. Hold motor assembly, and carefully take it out of fuselage.

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Centrifugal ventilator on back side of has bigger diameter than rotor rink, so motor will not
go out straight, as opening is now wide enough. You need to rotate it 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. Open ventilation fully - knob pushed forward.
2. It is recommended to use new bolt securing plates to secure M8 motor fixation
bolts.
3. Make sure that power cables are connected in the same order as before (check
taken photo for reference), as otherwise motor will not run, or it might run in wrong
direction. Use only new complete metal M6 self-locking nuts. Make sure that there is no
contact between cable shoes and aluminium mounting wall or M8 fixing bolts. Air gap
distance between each of these elements and each cable shoe should be at least 3mm.
Below the middle cable, should be placed M8 bolt which has more shallow head (one of 6
bolts which holds motor).
4. Carefully plug in male DB15 connector (with signal wires) into motor rear wall
female connector. Fix connector on both sides with lock springs.
After motor is reinstalled, check that:
•Spinner is nicely located in the centre 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 between 0,5-1mm. 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). If gap is wider than 1mm is not nice.
•All bolted connections assembled correctly and secured properly. Below six M8 bolts
which hold motor in place are thin brass safety spacers, which 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)

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9. Repair and service
In case of a fault or damage, please contact manufacturer.
10. Revision history
January 2019
Initial release of manual, v1.0
December 2020
Minor update of manual, v1.1