FES FES-HPH-M100 Manuel utilisateur

FES MOTOR MANUAL

Version 1.21

Type: FES-HPH-M100

Produced by:

LZ design d.o.o., Brod 3D, 1370 Logatec, Slovenia tel +386 59 948 898

[email protected] www.front-electric-sustainer.com

This Operation Manual Constitutes an EASA Approved Manual for propulsion unit item, in accordance with

Part21.A.23(b)(2), as engine and propeller are accepted as part of the sailplane. Holder of TC EASA.A. 030 is

responsible for information stated herein, it's changes, amendments and continuing airworthiness actions.

Released: Martin Pekař

Date: 18.11.2016

FES-HPH-M100 MOTOR manual Version 1.21 September 2016 
Page 2 of 14 
 
 
Table of Content 
 
Important notices..........................................................................................................................3 
1 Limited Warranty .....................................................................................................................3 
General ...........................................................................................................................................4 
Model designation.........................................................................................................................4 
Technical data and limitations of motor ....................................................................................5 
Drawing of motor..........................................................................................................................7 
Operating instructions ..................................................................................................................8 
1 Motor starting on the ground................................................................................................8 
2 Motor starting procedure during flight ................................................................................8 
3 Propeller stop with electronic braking .................................................................................9 
4 Propeller positioning...............................................................................................................9 
Maintenance.................................................................................................................................10 
Removal of motor .......................................................................................................................11 
Installation of motor...................................................................................................................13 
Repair and service ....................................................................................................................14 
Revision history .........................................................................................................................14 

FES-HPH-M100 MOTOR manual Version 1.21 September 2016

Page 3 of 14

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 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.

FES-HPH-M100 MOTOR manual Version 1.21 September 2016

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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-HPH-M100

(1)

(2)

(3)

where:

- (1) motor application

- (2) designed for sailplane model; HPH304ES

- (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.

NOTE: Motor type FES-HPH-M100 is identical like FES-DIS-M100. It is marked differently

due to different manufacturer of the sailplane.

FES-HPH-M100 MOTOR manual Version 1.21 September 2016

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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-HPH-M100 power ratings at 116V on motor controller and

loaded with FES-HPH-P1-102 propeller:

Maximum torque

75 Nm

Maximum current

200A

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-HPH-P1-100 propeller (1m diameter)

4500 rpm

Battery current loaded (4500 rpm, 116V) with FES-HPH-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!

FES-HPH-M100 MOTOR manual Version 1.21 September 2016

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Power Consumption

0; 0

Horizontal flight

Max climb

01000 2000 3000 4000 5000

n (RPM)

P (kw)

Power consumption curve

Rpm versus Power

FES-HPH-M100 MOTOR manual Version 1.21 September 2016

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5. Drawing of motor

FES-HPH-M100 MOTOR manual Version 1.21 September 2016

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6. Operating instructions

6.1 Motor starting on the ground

1. Remove propeller covers and a tail dolly

2. Open battery compartment cover

3. Check that Power switch is OFF

4. Insert connecting cable between the battery packs

5. Switch ON BMS switch of each battery pack

6. Seal battery compartment cover with glider tape

7. Seat into the glider, and close canopy

8. Check that no one is around propeller zone, in front of glider or in line of propeller

9. Switch on FCU instrument

10.Switch on Power switch

11.Wait about 8 second, for FCU to show all battery bottles

12.Start motor but use only low power to check proper operation

Caution

: In case that you would like to test, system at maximum power,

somebody must hold a fuselage tube down, so that glider can not lift tail,

which could result in damaged propeller blades.

Warning

: Do not run the motor for longer time, on the ground, especially

not at high power! When motor is stopped, also cooling is stopped, and so

motor temperature can rise very quickly, which can lead to damaged motor!

13.Check if propeller braking and automatic positioning are working fine

14.Switch OFF Power switch

15.Switch OFF FCU

6.2 Motor starting procedure during flight:

1. Check that all values on the FCU instrument are in normal range (FCU must be

always switched ON during flight)

2. Turn ON Power Switch

3. Check if there is green LED ON (left lower LED), check Voltage level

1. (If there is no green LED or red LED is blinking motor will not run). Read FES FCU

instrument manual for detailed FCU description

4. Start motor with Throttle knob rotating in clockwise direction gently.

Use about 4kW of power for horizontal flight, and more for climbing. Maximum climb

rate depends on glider type and it is affected by its weight, speed, flaps position etc.

Available maximum power is reducing slowly due to voltage drop, during discharging

of battery packs. Maximum power can be used only until any of temperature values reach

yellow warning. (motor and controller at 70 deg, battery packs at 45 deg)!

Do not use high current at lower voltages; this mean below 95V.

Always try to fly as much as possible on lower power settings where efficiency of

complete system is the highest!

During powered flight always keep the FCU turned ON. Switch OFF Power switch if

motor is not running.

FES-HPH-M100 MOTOR manual Version 1.21 September 2016

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6.3 Propeller stop with electronic braking

To stop propeller with electronic braking, you need to rotate Throttle knob in

counter-clockwise direction for 1 step, from zero throttle, so that throttle line on display

starts blinking red!

Note:

For successful stop the motor should reach about 1500 RPM,

otherwise braking will not work, due to insufficient induced voltage

(regeneration function of controller is used for propeller braking).

In the air there is nearly always enough RPM. But if you want to test

electronic braking on the ground, make sure you set at least 1500 RPM, and

then rotate throttle knob quickly in counter clockwise direction!

6.4 Propeller positioning

After electronic braking stops motor, wait for 2-3 second, until RPM data shows zero RPM.

After that automatic positioning will start! You can always stop automatic positioning by

pressing throttle knob.

Note:

Positioning does not work if Canopy message is active, or if throttle is

set to zero power instead of braking!

In settings it is possible to adjust:

-time between steps from 50ms to 1 sec

-power used for positioning at 115V and at 90V

-number of steps after hall sensor for position is detected

FES-HPH-M100 MOTOR manual Version 1.21 September 2016

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7. Maintenance

The motor do 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 has to 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 can not 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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