LZ design FES-VEN-M100 User manual

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

FES-VEN-M100 MOTOR manual Version 1.1 June 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................................................................................................. 9
9. Repair and service.................................................................................................. 10
10. Revision history .................................................................................................... 10

FES-VEN-M100 MOTOR manual Version 1.1 June 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.
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 labor, 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.
2020 ©LZ design. All rights reserved.

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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-VEN-M100
(1)
(2)
(3)
where:
- (1) motor application
- (2) designed for sailplane model; Ventus-2c 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 Aluminum plate of motor.

FES-VEN-M100 MOTOR manual Version 1.1 June 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 sensorless controllers.
Electrical motor type FES-VEN-M100 power ratings at 116V on motor controller and
loaded with FES-VEN-P1-102 propeller:
Maximum torque
75 Nm
Maximum current
200A
Maximum Voltage
180V
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-VEN-P1-100 propeller (1m diameter)
4500 rpm
Battery current loaded (4500 rpm, 116V) with FES-VEN-P1-102
up to 200 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. Higer 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

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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 millimeters. 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.

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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!
To remove the motor from the glider (complete with spinner and propeller)
1. Open ventilation (fully forward position)
2. Remove round laminated cover from center of front motor mounting rib (from
cockpit side)
3. Unlock springs which hold DB15 cable connector and than carefully unplug
connector from motor rear wall.
4. Unscrew 3 self-locking nuts from rear motor wall and disconnect 3 power cables.
Before disconnection is recommended to mark them as A, B, C, and draw their position
against each other on list of paper.
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.
8. Installation of motor
To install motor back on glider, follow the reverse order.
Take care about additional steps:
1. Open ventilation fully-lever 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 A, B, C like before
and use only new M6 self-locking nuts. Make sure that there is no contact between cable
shoes aluminum mounting wall or M8 fixing bolts. Below cables must be M8 bolt with
shorter head.
4. Carefully plug in signal wires connector into motor rear wall connector. Lock
springs which hold connector in place.
After motor is reinstalled, check the following:
•Spinner is in the center of fuselage
•Gap between spinner and fuselage is 0,5-1mm
•All bolted connections assembled correctly and secured properly
•Start the motor on a ground and run it for a few seconds to check:
•Motor rotating direction, smooth run of motor
•Braking of propeller works OK
•FCU instrument is functioning properly.

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9. Repair and service
In case of a fault or damage, please contact manufacturer.
10. Revision history
July 2015
Initial release of manual, Version 1.0
June 2020
Minor updates, updated photo of Motor, Version 1.1