Motors Burning

Do you run the motor at a low frequency through the inverter? If you do you may need to install a force cooling fan on the motor, because the standard shaft mounted fan becomes useless if the speed is decreased too much.

<Insert standard rant about using vague terminology and incomplete information>

I have no idea what a "Falcon" refers to, other than the bird, the US Football Team for Atlanta, a classic Ford automobile or a very fast fictional space ship piloted by Han Solo. You also didn't supply any meaningful data on the motor itself other than size and voltage rating.

So there are a number of potential issues, most already mentioned:

1. You are running the motor too slow and it does not have adequate cooling when you do. So either change the motor to one that is rated for inverter duty (if it isn't already) and/or supply a separately powered cooling fan.
2. You have a non-inverter rated motor and the distance from the drive to the motor is long, which allows for the creation of a phenomenon called "standing waves" that will damage the winding insulation. A good motor rewind shop can usually diagnose that as the cause of the failure by observing insulation breakdown in the first turns of the windings as they receive the brunt of the damaging high voltage spikes caused by the standing waves. Again, inverter duty motors use better insulation to withstand this, but there are also other mitigation methods that can be employed after the fact.
3. You have a motor that is too small for the load and you have set the protection circuit inappropriately for the task, although you did already post that you double checked it.
4. Your motor connection is not correct, i.e. you have it connected in Delta instead of Star. If it has been working fine and only recently had that problem this is not likely, but again, if you had used a more descriptive term for the machine / process that would have helped eliminate this. Some processes work fine for a long time with misconnected motors because the load is highly variable.
5. You have an ambient temperature problem and the added heating caused by the VFD is too much for the motor.
6. You failed to mention the failure mode of the motor, other than "burnt", which could mena a lot of things. Another potential issue is bearing failure because of static voltage discharges across the bearing races. The bearings get damaged, the rotor crashes into the stator, you see something "burnt".
   
7. You have a bad VFD.

There are probably more.