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41807744.eps
121201 EN
214 228 44
720 IS 919
Manufacturer
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FR
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ES
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Geared travel motors Volume 3 Quick selection and gearbox limit torque
Geared travel motors Volume 3 Quick selection and gearbox limit torque
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Operating instructions
Plug connection for KB and Z motors new design
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Contents
Foreword
0.1
0.2
0.3
0.4
0.5
Copyright
After-sales service
Guarantee
Limitations of liability
Definitions
4
4
4
5
5
Safety
1.1
1.2
1.3
1.4
Symbols
Intended use
Prohibited practises, improper use
Safety instructions
6
6
6
7
214228k1.p65/121201
214228k1.p65/121201
2.1
2.2
2.3
Receiving
Transport
Storage
8
8
8
Product description
3.1
3.1.1
3.1.2
3.2
Motor
Motor type designation
Rating plates
ZB. motor brake
Installation
13
4.1
4.2
4.3
4.4
4.5
13
13
13
13
13
9
9
10
12
Commissioning
14
5.1
5.2
5.3
Requirements
Check when commissioning
Geared motors
14
14
14
Maintenance
15
6.1
6.2
6.3
6.3.1
6.3.2
6.3.3
6.4
6.4.1
6.4.2
6.4.3
6.4.4
15
15
16
17
20
28
28
29
29
29
29
30
7.1
7.2
7.2.1
7.2.2
7.2.3
7.3
7.4
7.4.1
7.4.2
7.4.3
7.5
7.5.1
7.5.2
7.6
7.7
Brake control
Brake operating times
ZBA range brake operating times
ZBF range brake operating times
Brake power consumption
Selection criteria
Z motors standard connection diagrams to EN standards
ZBF travel motors
ZBA standard motors with brake
ZNA standard motors without brake
Connection diagram selection
Line operation
Inverter operation
Connection diagrams
Connecting temperature and brake monitoring devices
30
35
35
36
36
37
38
38
38
39
40
40
44
45
82
Technical data
83
Troubleshooting
84
10
85
EC conformity declaration
87
Foreword
You have purchased a Demag product. This equipment was manufactured in accordance with state-of-the-art engineering principles.
These operating instructions are designed to provide the operator with appropriate
instructions for safe and correct operation and to facilitate maintenance.
Every individual given the task of transporting, installing, commissioning, operating,
maintaining and repairing our Z.. motors and additional equipment must have read
and understood
the operating instructions
the safety regulations and
safety instructions in the individual chapters and sections.
The operating instructions must be available to the operating personnel at all times
in order to prevent operating errors and to ensure smooth and trouble-free operation of our products.
0.1 Copyright
0.3 Guarantee
These operating instructions contain all necessary information and must be read
carefully before installing and putting the product into operation.
We assume no liability for damage and malfunctions resulting from failure to comply
with the operating instructions.
Wearing parts are not subject to the guarantee, guarantee claims must be made by
quoting the order number to Demag immediately on detecting the defect.
The guarantee is cancelled, for example, in the event of:
inappropriate use,
faulty devices or equipment connected or attached to the product which are not
part of our scope of supplies and services,
use of non-genuine spare parts and accessories,
214228k1.p65/121201
All technical information, data and instructions for operation contained in these operating instructions were up-to-date on going to print and are compiled on the basis
of our experience and to the best of our knowledge.
We reserve the right to incorporate technical modifications within the scope of further development of the hoist units which are the subject of these operating instructions. The information, illustrations and descriptions contained in these operating
instructions are therefore only intended for information purposes.
The descriptions and illustrations contained in this documentation do not necessarily
correspond to the scope of delivery or any subsequent spare part delivery, either;
the drawings and illustrations are not to scale.
Only documentation belonging to the actual order is valid.
We assume no liability for defects, damage and malfunctions caused as a result of
operating errors, noncompliance with these operating instructions or omitted and/or
inappropriate repairs and maintenance.
We expressly point out that only Demag spare parts and accessories approved by
us may be used. Accordingly, this also applies to other manufacturers parts supplied by us.
For safety reasons, the fitting and use of spare parts or accessories which have not
been approved and unauthorized modification and conversion of the motors are not
permitted; we assume no liability for defects or damages resulting therefrom.
With the exclusion of any further claims, our warranty and liability obligations for any
defects pertaining to the products supplied or faults in the documentation delivered
or any negligence on our part are exclusively based on the stipulations of the original contract. Any further claims, in particular any and all claims for damages, are
excluded with the exception of legal claims in accordance with product liability legislation.
0.5 Definitions
Owner
Owners (employer, company) are defined as persons who own the product and
who use it appropriately or allow it to be operated by suitable persons.
Operating personnel
Operating personnel are defined as persons assigned by the owner of the product
to carry out special tasks such as installation, operation, setting-up, maintenance
including cleaning, fault elimination and transportation of the product.
Specialist personnel
Specialist personnel are defined as persons assigned by the owner to carry out
specific tasks.
Qualified personnel (electrician)
Qualified personnel (electricians) are defined as persons, who, owing to their
technical training, knowledge and experience as well as knowledge of the relevant standards, are able to assess the tasks given to them and identify potential
hazards.
Trained person
Trained persons are defined as persons who have been instructed and trained
for the tasks assigned to them and on the possible hazards resulting from incorrect handling and who have been informed about the required protective devices,
protective measures, relevant regulations, codes of practice, accident prevention
regulations and operating conditions and who have proven their qualifications.
214228k1.p65/121201
Experienced technician
Experienced technicians are defined as persons, who, owing to their technical
training and experience, have sufficient knowledge of the product and are familiar
with the relevant national industrial safety regulations, codes of practice, accident
prevention regulations, directives and generally accepted engineering standards
(e.g. EC Directives, German VDE and VBG regulations) enabling them to judge
the safe operating condition of Z.. motors.
Safety
1.1 Symbols
These motors may be used for all travel, lifting and turning motions in industrial
applications. Compliance with the permitted operating conditions must be ensured
for operation of these drives (e.g. enclosure type, ambient temperature, installation
height).
214228k1.p65/121201
Safety devices must not be rendered inoperable or modified or used in any way
other than that for which they have been designed.
1.4 Safety
instructions
The relevant national accident prevention regulations and the general safety conditions must always be observed when our products are operated in order to avoid
accidents and damage to machinery. If the safety instructions given in these operating instructions are not observed in any way, personal injury or even death can result.
Dangerous voltage!
Motors are connected to a mains power supply. Any contact with live parts can lead
to very serious injury or even death.
Do this only
if you have read the operating instructions and the owner has instructed you in all
details,
if the operating instructions are available for reference at the place of operation,
if you are qualified personnel,
if you are not under the influence of drugs, alcohol or medication that can adversely affect your ability to react,
if the general accident prevention, operating and installation regulations (e.g. DINVDE 0100/0113/0160) have been observed.
214228k1.p65/121201
2.1 Receiving
The scope of delivery is specified in the shipping papers. Check the delivery immediately on receipt to ensure that it is complete and examine it for damage caused in
transit. If necessary, a damage report must be made out in the presence of the
transport contractors representative as otherwise it will not be possible to rectify
the damage at no cost to you.
2.2 Transport
The drive is supplied made up into one unit. Additional equipment may be supplied
in separate packaging.
The drive is packed depending on the transport method and its weight. Unless
otherwise agreed in the purchase contract, the packaging corresponds to the packaging guidelines of Demag Cranes & Components.
Symbols used on the packing
This way up
Top-heavy
Fragile
No hooks
Keep dry
Centre of gravity
41283944
41284644.eps
Handle motors with utmost care to avoid damage caused by careless loading and
unloading, for example.
2.3 Storage
Unless otherwise agreed in the purchase contract, standard conservation is guaranteed for a period of 6 months. The guarantee period begins on the day the unit is
delivered.
Contact Demag Cranes & Components GmbH in Wetter, Germany, if geared motors are to be stored for periods of longer than 6 months.
214228k1.p65/121201
Product description
Demag type Z cylindrical rotor motors can be supplied with or without brake
(ZB and ZN motors). The ZBA and ZNA motor range includes frame sizes Z..63 to
Z..225. The output ratings of the 2, 4, 6 and 8-pole motors are graded according to
the IEC classification. The motor range includes pole-changing designs and motors
ZBF 63 ... 132 with integrated fly wheels for particularly smooth load movement.
3.1 Motor
The housings of motor frame sizes Z..63 to Z..132 are of a high quality aluminium
alloy with an integrated terminal box base. The terminal box cover and fan cover are
made of plastic.
Motor frame sizes Z..160 to Z..225 have a grey cast iron housing with a fitted
terminal box.
All motors can also be supplied in flange and foot design with shafts largely
corresponding to IEC shaft dimensions and connected to the Demag gearboxes.
Brake size
B003, B004, B007, B020, B050, B140, B280, B680
100
8/2
B 050
Number of poles
2, 4, 6, 8, 8/2, 8/4, 12/2
Rating class
A, AL, B, C
Size
63, 71, 80, 90, 100, 112, 132, 160, 180, 200, 225
Application code
A Motor for general applications with IEC ratings
F Motor for travel applications
Motor type
B Motor with brake
N Motor without brake
Motor type
214228k2.p65/121201
1
2
3
Typ:
ZBA 71 B 4 B007
Mot.Nr .: 71740301
kg
10,0
1380
230
400
Bremse: 5,1
Nm
ANR:
85674100
5
6
7
8
3 ~
FI: --1/min
V
V
AC 400 V
IP: 54
100
Hz
50
Iso : F
%ED
cos
2,50
1,40
DC 180
ASN: 00201
Made in Germany
EN 60034-1
IM B5-1
kW
0,37
0,60
c/h --C
A
A
0,14
V
A
EFF.
10
214228k2.p65/121201
41806344.eps
Demag
Made in Germany
Cranes & Components GmbH EN 60034-1
3
4
5
6
7
8
9
1
3
4
5
6
7
8
9
IP: 54
%ED
50 Hz
C
A
A
0,14 A
FI: --EFF.
41806444.eps
Rating plate for Z.. 160 A to Z.. 225 B motors with/without brake
2
3
4
5
Type:
ZBA 160 B4 B280
3 ~ IP 54 Iso.:
Mot.Nr: 12345678
100
%ED
183
kg
Fl:
50 Hz
cos :
1440
c/h
1/min
230
A
V 51,00
Y 400
V 29,0
A
V 0,45
Bremse: 187 Nm
AC 400 V DC 180
EFF.
ANR: 59021500 ASN:19301
214228k2.p65/121201
7
8
EN 60034-1
F IM B3-1
15,0
kW
0,84
40
C
Made in Germany
The rating plate is attached to the left or right next to the terminal box on the stator,
e.g.
A
41965544.eps
2
3
6
7
Demag B003 to B680 disk brakes are spring-actuated brakes featuring electromagnetic brake release. The brake fitted under the fan cover can be controlled independently of the motor and causes no axial movement of the rotor shaft or forces
on the bearings.
The diagrams show the function elements of the disk brakes, which are spring-actuated with electromagnetic release.
When the power supply to the brake coil is interrupted, the brake is applied. This
operating principle is also known as a fail-safe brake.
Brakes B003 to B680 can be released by a rectifier integrated in the terminal box of
the motor. For brakes B 003 to B 050 also by applying DC voltage direct to the brake
coil.
Two brake sizes are available for each motor frame size to cover a large brake
torque range for various applications.
2 18 4 16 6 7 15
17
1
2
3
4
5
6
7
8
9
10
11
12
42282444.eps
12
Magnet assembly
Radial shaft sealing ring
Friction plate
Sleeve
Grub screw
Distance spring
13
14
15
16
17
18
12
14
Sealing washer
Adjusting nut
Brake spring
Armature disk
Collared pin
Friction plate, stainless steel, (for ZBA
motors with brakes B 004 B 050)
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214228k2.p65/121201
B 003 DC brake
Installation
Before installing the motor, check whether it has suffered any damage during transportation or while in storage, such as corrosion, leaks, deformation or breakage.
The standard drive is suitable for operation in normal industrial conditions. If the
ambient temperature, atmosphere or humidity are other than indicated on the rating
plate, the motors must only be operated with special equipment or features (see
rating plate).
Ambient temperature:
Installation height:
from 10 C to +40 C
up to 1000 m above sea level
The site at which motors are installed must be designed in such a way that
air may circulate to allow heat to be exchanged and that warm air is not inducted again immediately,
no residue from operating processes can accumulate on the motor, fall between the drive elements or damage the sealing ring,
the rating plate is accessible.
Before installing the motor, check that it will be operated in the mounting position
specified on the rating plate.
If the motor is operated outdoors in vertical mounting position IM V1 or in an inclined mounting position with the shaft facing downwards, it should be protected by
a canopy provided by the customer.
For motors with condensation water openings which can be closed with a threaded
plug, the drain holes must be arranged at the lowest point of the motor as otherwise
water may enter. If the mounting position of the motor is changed and the drain
holes are no longer required, the openings must be closed and permanently sealed.
You must be a trained electrician and familiar with the relevant accident prevention regulations and codes of practise.
The motor and connecting cable must be disconnected from the supply.
The frequency and voltage specified on the rating plate must correspond to the
line frequency and voltage.
The motor must be connected as described in section 7 Motor/brake connection
diagrams .
214228k2.p65/121201
Pins
M4
90 B, 100
M5
M6
M8
To change the direction of rotation of the motor, two of the three phase conductors
must be interchanged.
The instructions contained in section 5 Commissioning must be followed!
13
Commissioning
5.1 Requirements
214228k2.p65/121201
14
Maintenance
If defects or damage are detected, the motor must not be put into operation
or taken out of service. It may only be put back into service when the defect
has been eliminated.
Check
Action
External damage
214228k2.p65/121201
Interval
Part
Maintenance
Brake
Motor
See section
6.3.1 and 6.3.2
15
B 003 brake:
Sealing tape is standard.
At present, the manual brake release unit is only available for brakes
B 004 B 680.
Micro-switches are not provided.
B 004 B 680 brakes:
The brake spring values refer to the motor design WITHOUT manual
brake release unit.
Apart from wear, the brake is virtually maintenance-free.
The brake lining is designed in such a way that worn surface particles are only given
off as minimal abrasion. This built-in regeneration of the brake lining surface ensures
constant braking characteristics. It is advisable to check the brake air gap s1 at certain intervals and to adjust it as necessary to ensure the brake releases reliably.
Brake size
B 003
B 004
B 007
B 020
Motor
B 050
B 140
B 280
B 680
ZBA
0,3
0,3
0,3
0,3
0,3
0,35
0,4
0,4
1,0
0,65
0,65
0,65
0,65
1,3
1,3
1,3
0,3
0,3
0,3
0,3
0,35
1,2
1,2
1,2
1,2
1,2
Motor
ZBF
When the brake is released (power applied to brake coil), the brake disk can be freely
turned.
It is only possible to give guide values for brake operation until adjustment as they
depend on the given operating conditions.
B 003
B 004
16
B 00 7
B 020
B 050
B 140
B 280
B 680
Motor
ZBA
160 10 6
100 10 6
100 10 6
120 10 6
ZBF
200 10 6
200 10 6
300 10 6
500 10 6
900 10 6
When the brake has been adjusted several times, the remaining thickness bmin of the
brake disk must be checked.
B004 B680 brakes
The guide pins feature an easily visible marking which clearly indicates the minimum
dimension (see section 6.3.1).
B003 brake
The brake can be adjusted twice. After the second adjustment, check remaining
thickness b min of the brake disk at regular intervals.
This brake can only be checked visually.
B003 B680 brakes
The brake disk must be replaced when the remaining thickness is too small or wear
differs considerably between the two linings. A wear part set is available for replacement. In addition to the brake disk and the required small parts, the set also includes
the assembly instructions.
214228k3.p65/121201
Brake size
For a general overhaul, overhaul sets and wear part sets are available
ZBA motors
Overhaul set
Brake size
ZBA 63
ZBA 71
ZBA 80
ZBA 9 0 A
ZBA 90B
ZBA 100
ZBA 112A
ZBA 132
ZBA 160
ZBA 180A
ZBA 180B
ZBA 200
ZBA 225
B 003
260 960 84
260 962 84
B 004
260 963 84
260 965 84
B 007
260 966 84
260 967 84
260 970 84
B 020
260 971 84
260 972 84
260 975 84
B 050
260 976 84
260 977 84
260 980 84
B 140
260 981 84
260 982 84
260 984 84
B 280
260 985 84
260 986 84
260 987 84
B 680
260 988 84
260 989 84
260 990 84
ZBF motors
Overhaul set
Brake size
ZBF 80
ZBF 90B
ZBF 100
ZBF 112A
ZBF 132
B 003
260 960 84
260 962 84
B 004
260 964 84
260 965 84
B 020
260 973 84
260 974 84
260 975 84
B 050
260 978 84
260 979 84
260 980 84
B 140
260 983 84
260 984 84
The air gap s1 must be adjusted when the max. permissible value has been reached,
(however, immediately if the brake no longer releases).
If the brake is not adjusted, it will no longer release after further wear. If the
motor then operates against the applied brake, the brake and motor may be
damaged and fail.
6.3.1 Checking and adjusting the
brake air gap s1
214228k3.p65/121201
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and fan.
41432144.eps
41432244.eps
17
B004
B007
B020
B050
B140
B280
B680
8,5
10
11
1) If armature disk edge (2) has reached the mark (x) on guide pin (4), brake disk (3) must be replaced.
For replacing the brake disk, see section 6.3.2.
2) If the remaining thickness of the brake disk is within the specified tolerances, check brake air gap s1
(see checking/adjusting the brake air gap on pages 18/19).
B004-B680 brakes
Status when new
B003 brake
The B 003 brake can only be checked visually.
42028944.eps
41777744.eps
ZBA/ZBF motor
B003 brake
Checking/adjusting the brake air gap
Brake air gap s1min = 0,30 mm s1max= 1,0 mm (ZBA)
Brake air gap s1min = 0,30 mm s1max= 1,2 mm (ZBF)
Tighten magnet assembly (9) with the three hexagon screws (10) uniformly until the air gap is zero.
Loosen the three hexagon nuts (10) by angle a1 = 120.
Check air gap s1 using a feeler gauge at three points around the circumference. If the measured result is within the
specified range, the motor can be re-assembled.
If this is not the case, adjust again as required.
Magnet assembly (9)
Feeler gauge
Brake disk (3)
Friction plate (14)
18
41777344.eps
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214228k3.p65/121201
B004-B680 brakes
Checking/adjusting the brake air gap
Brake size
B 004
B 007
B 020
B 050
Motor
B 140
B 280
B 680
0,3
0,35
0,4
0,4
0,65
1,3
1,3
1,3
ZBA
0,3
0,3
0,3
0,65
0,65
0,65
Motor
ZBF
0,3
0,3
0,3
0,35
1,2
1,2
1,2
1,2
B050
B140
B280
B680
Tighten magnet assembly (9) with the three hexagon nuts (10) uniformly until the air gap is zero.
Loosen the three hexagon nuts (10) by angle a1.
Brake size
B004
B007
B020
Motor
ZBA
Adjusting angle a
120
Motor
120
120
90
80
70
60
120
90
80
ZBF
Adjusting angle a
120
Check air gap s1 using a feeler gauge at three points around the circumference. If the measured result is within the
specified range, the motor can be re-assembled.
If this is not the case, adjust again as required.
ZBA motor
ZBF motor
B004-B050 brakes
B004-B050 brakes
Feeler gauge
Brake disk (3)
42288844.eps
ZBA motor
42029144.eps
ZBF motor
B140 brake
Feeler gauge
214228k3.p65/121201
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19
Tightening torque
ZB. 63 100 motor = 4 Nm
ZB. 112 132 motor = 6 Nm
ZB. 160 225 motor =10,5 Nm
41431945.eps
41432144.eps
This work may only be carried out by authorised personnel. Observe relevant safety
regulations and section 1 Safety instructions.
Damaged brakes may only be repaired by a Demag authorised workshop.
41431944.eps
20
and fan.
41432144.eps
41432244.eps
214228k3.p65/121201
B004-B680 brakes
B003 brake
42022544.eps
42508644.eps
B003 brake
B004-B680 brakes
Remove stop plate (1), friction plate (2), distance springs (5)
and brake disk (3).
Check grub screws (4), sleeve (13) and braking surfaces for
wear.
Remove stop plate (1), armature disk (2), distance springs (5) and
brake disk (3).
Check collared pins (4) and braking surfaces for wear.
214228k3.p65/121201
42508344.eps
42288144.eps
21
42287944.eps
42508444.eps
Tightening torque
22
B003/004
B007
B020
B050
B140
B280
B680
3 Nm
3 Nm
4 Nm
9 Nm
30 Nm
70 Nm
140 Nm
214228k3.p65/121201
B003 brake
B004-B680 brakes
42288144.eps
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B003 brake
ZBA/ZBF motor
214228k3.p65/121201
33 wt
ws
rt
33 rd
Spring
arrangement
blue yellow
Part no.
Nm
white
red
2,5
1)
260 010 84
1,9
2)
260 011 84
1,4
3)
260 027 84
0,9
4)
260 013 84
3)
2)
1)
Brake torque
see item
4)
3 bl
yl
33 ge
42506845.eps
23
B004-B680 brakes
ZBA motor
Push distance spring (5) onto collared pins / grub screws (4).
Place brake springs (8) into magnet assembly (9).
For arrangement of brake springs (8) see the following table.
Brake
spring (8)
Push magnet assembly (9) over collared pins / grub screws and sleeves (4)
and secure with hexagon nut (10).
Then tighten the magnet assembly (9) with the three hexagon nuts (10)
uniformly until the air gap is zero.
Loosen the three hexagon nuts (10) by angle a1.
Check air gap s1 using a feeler gauge at three points around the circumference. If the measured result is within the specified range, the motor can be
re-assembled.
For checking/adjusting the brake air gap, see section 6.3.1.
Pull the connecting cable of magnet assembly (9) back into the terminal box.
Fit terminal box cover (11).
42022444.eps
Brake size
B 004
B 007
B 020
B 050
B 140
B 280
B 680
Adjusting angle a 1
120
120
120
90
80
70
60
260 110 84
260 210 84
260 310 84
260 410 84
260 510 84
260 610 84
Spring red
260 111 84
260 111 84
260 211 84
260 311 84
260 411 84
206 511 84
260 611 84
Spring blue
260 127 84
260 227 84
260 327 84
260 427 84
Brake spring
Part no.
Spring white
Arrangement of brake springs for motor without manual brake release unit
B 004
Number of springs
24
white
red
blue
B 007
B 020
B 050
B 140
B 280
B680
680
Brake torque M B in Nm
7,6
20
50
140
280
5,9
16
39
105
220
530
5,1
13
33
94
185
450
3,8
10
25
70
140
340
3,4
22
62
125
300
10
2,5
6,6
17
47
93
230
11
1,7
1,7
4,4
11
31
62
150
115
12
1,3
1,3
3,3
8,3
23
46
13
2,3
14
1,8
15
1,2
16
0,9
214228k3.p65/121201
Brake size
6 wt
ws
20)
6 ws,
wt, 2rd
2
2 rt
14)
rd
3 rt
4 rd
rt
16)
19)
44
rd,rt,11bl
bl
3 bl
6 bl
rd,22blbl
44 rt,
18)
17)
4 bl
wt
3 3ws
13)
12)
66 rd
rt
15)
3
3 wt,
ws, 3rd
3 rt
wt, 2rd
4 ws,
2rt
11)
10)
9)
8)
7)
6)
5)
rd,1bl
1 bl
3 rt,
rd,1bl
1 bl
5 rt,
22)
21)
11rt,
rd,55blbl
4 bl
5 bl
= wt,
white spring
= Bore hole,
empty
= rd,
red spring
= bl,
blue spring
= ye,
yellow spring
42506846.eps
Arrangement of brake springs for motor with manual brake release unit
Brake size
B 004
214228k3.p65/121201
Number of springs
white
red
blue
B 007
B 020
B 050
B 140
B 280
B 680
Brake torque MB in Nm
7,6
20
50
140
280
680
5,9
16
39
105
220
530
5,1
13
33
94
185
450
3,8
10
25
70
140
340
3,4
22
62
125
300
10
2,5
6,6
17
47
93
230
17
1,7
4,4
11
31
62
150
18
1,3
3,3
8,3
23
46
115
17
1,7
18
1,3
19
2,3
20
1,8
21
1,2
22
0,9
25
Brake
spring (8)
Push magnet assembly (9) over collared pins / grub screws and sleeves (4)
and secure with hexagon nut (10).
Then tighten the magnet assembly (9) with the three hexagon nuts (10)
uniformly until the air gap is zero.
Loosen the three hexagon nuts (10) by angle a1.
Check air gap s1 using a feeler gauge at three points around the circumference. If the measured result is within the specified range, the motor can be
re-assembled.
For checking/adjusting the brake air gap, see section 6.3.1.
Pull the connecting cable of magnet assembly (9) back into the terminal box.
Fit terminal box cover (11).
42022444.eps
Brake size
B 004
B 020
B 050
B 140
Adjusting angle a 1
120
120
90
80
260 210 84
260 310 84
260 410 84
Spring red
260 111 84
260 211 84
260 311 84
260 411 84
Spring blue
260 127 84
260 227 84
260 327 84
260 427 84
Brake spring
Part no.
Spring white
Arrangement of brake springs for motor without manual brake release unit
Brake size
B 004
Number of springs
red
blue
B 020
B 050
B 140
Brake torque M B in Nm
26
2,3
5,6
13
37
27
1,7
4,4
11
31
28
1,3
3,3
8,3
23
29
1,8
(3,3)
6,3
18
30
1,2
2,2
4,2
12
31
0,9
1,7
3,2
8,8
Arrangement of brake springs for motor with manual brake release unit
Brake size
B 004
Number of springs
26
B 020
B 050
B 140
Brake torque M B in Nm
blue
32
2,3
5,6
13
33
37
34
1,7
4,4
11
31
35
1,3
3,3
8,3
23
36
1,8
(3,3)
6,3
37
18
38
1,2
2,2
4,2
12
30
0,9
1,7
3,2
8,8
214228k3.p65/121201
red
26)
4 rd,
bl
rt, 22 bl
44 rd
rt
55 rd,
bl
rt, 11 bl
3 bl
37)
36)
34)
5 rt
rd
4 bl
35)
rd,11blbl
33 rt,
rd,11blbl
44 rt,
38)
1rt,
1 rd,4 4blbl
11rt,
rd,55blbl
= wt,
white spring
= Bore hole,
empty
30)
6 bl
3 rd
rt
33)
32)
31)
29)
28)
5 bl
= rd,
red spring
= bl,
blue spring
= ye,
yellow spring
42506946.eps
214228k3.p65/121201
41432144.eps
27
The bolts on Demag Z.. range motors must be tightened with the torques given in the
table below. This also applies when high tensile bolts are used.
Tightening torques of bolts
For hexagon socket bolts to DIN 912 and to DIN 6912 for IM B 14 flange mounting
Bolt size
Tightening torque
M5
M6
M8
M 10
M 12
M 16
6,2 Nm
10,5 Nm
25 Nm
50 Nm
86 Nm
215 Nm
IM B 3 foot mounting
IM B 5 flange mounting
M5
M6
M8
M 10
M 12
M 16
Tightening torque
for cast iron
7,5 Nm
14 Nm
30 Nm
65 Nm
100 Nm
270 Nm
Tightening torque
for cast aluminium
9 Nm
18 Nm
45 Nm
75 Nm
6.4 Options
28
214228k3.p65/121201
Micro-switches
A micro-switch arrangement is only possible for brake types B 004 B 680, not for
B003 brakes.
6.4.1
41766444.eps
41766544.eps
41766644.eps
41766644.eps
214228k3.p65/121201
41766544.eps
41766444.eps
For motors with manual brake release unit, also comply with the Additional equipment for brakes, ZBA ZBF motor range operating instructions, ident. no.
214 040 44.
6.4.4 Micro-switches
For motors with integrated micro-switches, also comply with the Additional equipment for brakes, ZBA ZBF motor range operating instructions, ident. no.
214 040 44.
29
Various control modules are available which are fitted in the brake motor terminal box
as standard for controlling Demag B003 to B680 disk brakes with DC magnets.
All modules can also be integrated in the control cubicle. The brake coil must then be
protected by means of a varistor (part no. 260 898 84) to protect the modules against
switch-off voltage peaks.
Brakes up to size
B050 for ZBA motors
B140 for ZBF motors
featuring 24 V DC coil voltage must be supplied and controlled by the installation
control system.
All rectifiers feature varistor protection against overvoltage at the AC input and on the
switching contact terminal as standard.
GE and GS brake rectifiers can be fed separately with alternating current or connected parallel to the motor winding. GP and GF brake rectifiers are particularly suitable
for pole-changing motors with parallel AC supply to the motor winding. All brake
rectifiers can be used for a max. alternating current of 500 V AC.
AC or DC brake control is possible with GE, GS and GP rectifiers depending on the
connection.
The control system is of modular design. SE or VE modules for fast DC interruption of
the brake current can be added to brake motors fitted with GE, GS or GP brake
rectifiers, also at a later date, without the need for additional cables and switching
devices.
The GF control module features integrated switch-off in the DC circuit.
Brake application times are highly dependent on the way in which the brake is connected.
UBrake [DC]
230 V
400 V
104 V
180 V
30
214228k4.p65/121201
Note:
214228k4.p65/121201
31
Part no.
Voltage range
260 892 84
in V
1)
Remarks
A
1,5
GE
260 890 84
42 ... 500
260 893 84
1,5
260 891 84
42 ... 500
GS
260 894 84
VE
260 897 84
42 ... 500
GP
260 864 84
260 870 84
32
260 943 84
3)
42 ... 500
0,8 ... 16 A
0,8
260 896 84
GF
1,2 ... 50 A
1)
Sinusoidal voltages
2)
2 leads
3 leads
Over-excitation factor of 2
Over-excitation factor of 2,5 (required from brake size B 140 for ZBA motors)
3)
Standard:
Rated motor current equal to or smaller than the higher value stated under "Control current range" of the SE current relay
214228k4.p65/121201
SE
2)
1)
Brake size
U AC
V
U DC
V
B 003
B 007
B 020
42 109
19 49
GE [3,0 A]
GP [3,0 A]
110 500
50 225
GE [1,5 A]
GP [1,5 A]
GS [1,0 A]
190 500
86 225
260 500
117 225
220 500
99 225
B 050
B 140
B 280
B 680
GS [1,0 A]
GS [1,0 A]
GS [1,0 A]
GF [0,8 A]
1)
B 00 7
B 020
B 050
Brake voltage
B 140
Brake voltage
B 280
B 680
Brake voltage
U AC
V
U DC
V
U AC
V
U DC
V
U AC
V
U DC
V
42 - 500
19 - 225
53 - 500
24 - 225
110 - 500
50 - 225
SE 2A
VE 2A
214228k4.p65/121201
U AC
U DC
33
Brake
Supply
voltage
ZBF
ZBA
Remark
ZBF
single -speed or
pole-changing
Part no.
singlespeed
Part no.
polechanging
Part no.
[ V AC]
42 - 109
GE [3,0 A]
260 890 84
a)
+ SE 1)
2,5 Nm
2,5 Nm
B 003
110 - 500
GE [1,5 A]
260 892 84
Voltage range:
+ SE 1)
42 - 109
7,6 Nm
GE [3,0 A]
19 - 225 V DC
260 890 84
+ SE 1)
B 007
110 - 500
GE [1,5 A]
b)
260 892 84
1)
5,5 Nm
GE [3,0 A]
110 - 500
GE [1,5 A]
GE [3,0 A]
260 892 84
1)
260 890 84
1)
B 050
110 - 500
GE [1,5 A]
42 - 109
140 Nm 37,3 Nm
GE [3,0 A]
+ SE
260 892 84
1)
260 890 84
1)
680 Nm
110 - 500
GS [1,0 A]
260 892 84
42 - 189
190 - 500
GS [1,0 A]
260 894 84
42 - 259
260 - 500
GS [1,0 A]
260 894 84
Exception:
B 140 brake with braking
torque 37,3 Nm
B 280
B 680
Voltage range:
19 - 225 V DC
The SE modules are allocated as follows depending on the rated motor current:
Module
4A
16 A
50 A
34
+ SE 1)
Part no.
260 864 84
SE
260 870 84
260 896 84
214228k4.p65/121201
1)
B 140
+ SE 1)
280 Nm
220 - 500 V AC
B 020
+ SE
13,2 Nm
260 890 84
+ SE 1)
42 - 109
50 Nm
Brake application times are highly dependent on the way in which the brake is connected.
Direct current connection
The coil circuit is interrupted when the brake module contact opens at the relevant
terminal. The magnetic field rapidly decreases and the brake torque rapidly rises.
Demag rectifiers are protected against overvoltage at the switching contact by
varistors.
Interruption of the DC circuit between the module and the coil connections
is not permitted.
Connection in the AC circuit
When the brake voltage is switched off, i.e. on the supply side before the rectifier,
an inductive coil current continues to flow through the rectifier diodes for a short
time. The magnet field decreases more slowly. The braking operation begins more
smoothly.
This connection type is not suitable for hoist drives.
Connection in the motor circuit
The rectifier is connected directly to the motor terminals. When the motor is
switched off, the residual motor voltage results in significantly longer switch-off
times compared to switch-off in the AC circuit.
Unless provided with switch-off in the DC circuit using a contact or the SE
current relay, this type of connection is not suitable for drives with overhauling loads, e.g. hoists, and may not be used in these applications.
Depending on the type of connection, the release and braking operation of B003 to
B680 DC brakes can generally be characterized by the following values:
Brake release time with normal excitation (GE, GP, GF) 1)
Brake release time with high-speed excitation (GS) 1)
Brake application time for switch-off in the AC circuit
Brake application time for switch-off in the DC circuit (contact)
Brake application time for switch-off in the DC circuit (SE, GF, VE)
t11
t12
t21
t22
t23
1)
Definition: The brake release time is the period of time which elapses until
the full accelerating torque of the motor is available.
Brake release times may be reduced using high-speed excitation modules with which
a higher voltage is temporarily applied to the brake coil when the brake is turned on
and the magnetic field is built up more quickly.
214228k4.p65/121201
Size
Release time in ms
Application time in ms
t 11
t 12
t 21
t 22
t 23
B 003
75
60
175
55
75
B 004
60
35
200
30
40
B 007
120
60
90
30
40
B 020
130
90
40
20
30
B 050
120
100
90
30
60
B 140
110
60
30
40
B 280
140
300
90
130
B 680
140
300
150
190
The brake release and application times given are guide values for the maximum
brake torque (see table above). In the case of lower brake torques, these values may
change, particularly t 21 for switch-off in the AC circuit.
35
Size
Release times in ms
Application times in ms
t 11
t 12
t 21
t 22
t 23
B 003
75
60
175
55
75
B 004
60
35
200
30
40
B 020
60
40
300
50
60
B 050
80
65
300
60
70
B 140
110
90
350
100
100
The brake release and application times given are guide values for the maximum
brake torque (see table above). In the case of lower brake torques, these values may
change, particularly t 21 for switch-off in the AC circuit.
Excitation with
GE, GF or GP module
A
Holding current
A
Release current
A
Holding current
A
B 003
0,11
0,22
0,11
0,28
0,11
B 004, B 007
0,13
0,26
0,13
0,33
0,13
B 020
0,15
0,30
0,15
0,38
0,15
B 050
0,21
0,42
0,21
0,53
0,21
B 140 1)
0,25
0,50
0,25
0,63
0,25
1,13
0,45
1,80
0,71
B 280
B 680
Note:
1)
Operation of the B140 brake with GE module or with an over-excitation factor of 2 with GS module
is only permissible up to a brake torque of 37,3 Nm.
With normal excitation, release current and holding current are identical.
The release currents for excitation with GS module are applied for approx. 300 ms.
36
1)
B 003
0,98
B 004
0,90
B 007
0,90
B 020
1,19
B 050
1,75
B 140 1)
1,73
Operation of the B 140 brake is only permissible up to a brake torque of 37,3 Nm.
214228k4.p65/121201
Note:
Current consumption
The following criteria must be considered when selecting the connection diagram:
Brake motor or motor without brake
Motor to be operated with
one line voltage (e.g. 400 V, 50 Hz) or
two line voltages (e.g. D/Y 230/400 V 50 Hz or YY/Y 240/480 V 60 Hz)
Motor designed for one or two speeds
Common or separate power supply to motor and brake
Control module selected:
GE for normal excitation
GS for high-speed excitation
GP for normal excitation for pole-changing motors
GF for pole-changing ZBF motors
Switch-off:
in the DC circuit for short operating times (e.g. hoist drives, positioning drives
in the AC circuit for medium operating times (e.g. travel drives, conveyor belts)
in the motor circuit for stopping the motor in an uncritical time.
Refer to the following flow charts and selection tables.
Notes:
214228k4.p65/121201
The terminal designations used in the connection diagrams are printed on the white motor connecting leads. The designations on the
terminal board in the motor apply to single-speed motors with 6 connecting leads.
37
Brakes
Control
module
500V
Sizes
63 132
UM
U Br
Line voltage
B 003 B 140
GE + SE
UBr = UM
Example
Line:
UM:
UBr:
400V
Connection
diagram
037 882 84
> 500V
Example
UBr = UM / 3
Line:
UM:
U Br :
Connection
diagram
525V
525V
300V
037 858 84
Motor voltage
Brake voltage
Brake
Control
module
500V
Sizes
63 100
Line voltage
B 003 B 050
GF
UBr = UM
112 132
B 140
GP + SE
Example
Line:
UM:
UBr:
Connection
diagram
038 337 84
400V
> 500V
Example
UBr = UM / 3
037 873 84
Line:
UM:
UBr:
525V
525V
300V
Connection
diagram
038 423 84
038 421 84
U M Motor voltage
U B r Brake voltage
Control
module
500 V
Sizes
63 132
Line voltage
B 003 B 050
GE
UBr = UM
132 225
38
B 140 B 680
Example
GS
three-phase
supply
UM
U Br
Motor voltage
Brake voltage
1)
2)
Line:
UM:
UBr:
Connection
diagram
> 500 V
Example
037 875 84
U B r = UM / 3
Line:
UM:
UBr:
525 V
525 V
300 V
038 006 84
U B r 500 V
Line:
UM:
UBr:
525 V
525 V
500 V 1)
400 V
1)
Connection
diagram
037 857 84
037 859 84
2)
214228k4.p65/121201
ZBA motors
Brake
Control
module
500V
Sizes
63 132
B 003 B 050
132
B 140
160 225
B 140 B 680
Example
Connection
diagram
GE
GS
three-phase
supply
UM
U Br
Motor voltage
Brake voltage
1)
2)
Line voltage
> 500V
Example
Connection
diagram
038 425 84
037 860 84
U Br = U M
Line:
U M:
U Br:
400V
400V
400V
038 001 84
U Br 500V 1)
Line:
U M:
U Br:
525V
525V
500V 1)
038 427 84
038 017 84 2)
038 017 84
Brake
Control module
Connection diagram
63 132
B 003 B 050
GE 1)
037 880 84
132 225
B 140 B 680
Sizes
1)
GS 1)
three-phase supply
038 015 84
ZNA motors
Connection diagram
214228k4.p65/121201
sizes
One speed
63 225
020 323 84
63 132
020 332 84
160 225
028 857 84
63 225
020 328 84
39
2 windings (Y/Y)
up to size 132
Voltage > 500V
yes
Table 1
no
Special connection
diagram
yes
yes
Table 2
no
Motor with brake?
no
1 line voltage?
yes
1 speed?
yes
Table 3
no
no
2 line voltages,
dual-voltage motor
1 line voltage?
yes
no
2 speeds
Table 4
1 speed
Table 5
Common
power supply to
motor and brake?
yes
Table 6
no
B 003 to B 680
DC brake
Separate
AC power supply
yes
Table 7
no
2 line voltages,
dual-voltage motor
Separate
DC power supply
B003 to B 680
DC brake
Common
power supply to
motor and brake?
Table 8
yes
Table 9
no
yes
Table 10
no
Separate
DC power supply
40
Table 11
41808755.eps
214228k4.p65/121201
Separate
AC power supply
General overview
Tables 1 2
1
Switch-off 1)
Power supply
common
gs with SE
internal
separate, AC
gs with SE
gs with VE
Brake size
ZBF
GP
B 050
B 140
038 420 84
B 140
B 050
B 140
038 421 84
B 140
B 050
B 140
038 423 84
B 140
B 050
B 140
038 425 84
038 426 84
B 140
038 427 84
B 050
B 140
038 429 84
038 431 84
B 140
038 433 84
B 050
B 140
038 430 84
038 432 84
GE
GS
n one
B 140
038 434 84
gs with contact
B 050
B 140
038 428 84
none
none
038 435 84
gs
ws
ms
2)
DC circuit
AC circuit
motor circuit
214228k4.p65/121201
GF 2 )
ZBA
separate, DC
1)
1)
Connection
diagram
Windings
Voltages
Modules
Switch-off in 1)
Special
038 021 84
2 ( Y/ Y )
GE + SE
gs
038 186 84
1 ( YY / Y )
GE
gs, ws, ms
038 187 84
1 ( YY / Y )
GE + SE
gs
038 338 84
2 ( Y/ Y )
GF
gs
038 422 84
2 ( Y/ Y )
1, > 500 V
GE + SE
gs
038 424 84
2 ( Y/ Y )
1, > 500 V
GF
gs
gs
ws
ms
DC circuit
AC circuit
motor circuit
41
Tables 3 5
Motor type
one speed
020 323 84
Motor type
two speeds
(separate windings)
Y/Y
D/Y
020 332 84
028 857 84
Motor type
one speed
Tables 6 11
020 328 84
D/Y
YY/Y
020 323 84
020 337 84
Motor type
one speed
two speeds
(separate windings)
D/Y
Y/Y
Switch-off in
Switching
element
ZBA
ZBF
DC circuit
Contact
B 050
B 140
B 140
1) 2)
B 050
B 140
B 140
038 008 84
internal
B 050
Contact
B 050
B 140
B 140
B 050
B 140
B 140
SE
AC circuit
motor circuit
1)
2)
GS
GF 2)
GP
038 006 84
038 006 84
038 006 84
Motor type
one speed
two speeds
(separate windings)
Switch-off in
Switching
element
DC circuit
Contact
SE
1) 2)
VE 1 )
AC circuit
Contact
ZBF
B 050
B 140
B 140
B 050
B 140
B 140
B 050
B 140
B 140
B 050
B 140
B 140
two speeds
(Dahlander winding)
D/Y
Y/Y
42
1)
GS
038 337 84
GE
GS
GE
GS
038 006 84
038 008 84
038 007 84
038 006 84
GE
GS
038 015 84
038 016 84
038 015 84
214228k4.p65/121201
two speeds
(Dahlander winding)
Motor type
one speed
Switch-off in
DC circuit
Switching
element
Contact
two speeds
(Dahlander winding)
ZBA
ZBF
B 050
B 140
037 897 84
037 898 84
037 871 84
Motor connection
two speeds
(separate windings )
D /Y
YY/Y
Switch-off in
Switching
element
ZBA
ZBF
GE
GS
GE
GS
DC circuit
Contact
B 050
B 140
037 857 84
037 883 84
037 863 84
037 889 84
B 140
037 859 84
038 004 84
1) 2)
B 050
B 140
037 858 84
037 884 84
037 864 84
037 890 84
SE
AC circuit
Contact
motor circuit
1)
2)
B 140
037 865 84
038 005 84
B 050
B 140
037 857 84
037 883 84
037 863 84
037 889 84
B 140
037 859 84
038 004 84
B 050
B 140
037 857 84
037 883 84
037 863 84
037 889 84
B 140
037 859 84
038 004 84
Motor connection
10
D/Y
Switch-off in
DC circuit
Switching
element
Contact
SE
1) 2)
VE
AC circuit
1)
2)
1)
Contact
YY/Y
ZBA
ZBF
GE
GS
GE
GS
B 050
B 140
037 857 84
037 883 84
037 863 84
037 889 84
B 140
037 859 84
038 004 84
B 050
B 140
037 858 84
037 884 84
037 864 84
037 890 84
B 140
037 865 84
038 005 84
B 050
B 140
037 876 84
037 893 84
037 881 84
037 896 84
B 140
038 007 84
038 014 84
B 050
B 140
037 857 84
037 883 84
037 863 84
037 889 84
B 140
037 859 84
038 004 84
Motor connection
11
D/Y
Switch-off in
214228k4.p65/121201
DC circuit
Switching
element
Contact
ZBF
B 050
B 140
YY/Y
No control module in terminal box
037 897 84
037 899 84
43
no
Table 12
yes
Separate AC
power supply
B004 B 680
DC brake
yes
Table 13
no
Separate DC
power supply
Table 14
41808844.eps
Tables 12 14
Motor type
12
one speed
D /Y
one speed
Y/YY
020 323 84
020 337 84
Motor type
13
one speed
D /Y
Switch off in
Switching
element
ZBA
ZBF
GE
GS
GE
GS
DC circuit
Contact
B 050
B 140
037 875 84
037 892 84
037 863 84
037 889 84
B 140
038 006 84
038 004 84
VE 1 )
B 050
B 140
037 876 84
037 893 84
037 881 84
037 896 84
AC circuit
B 140
038 007 84
038 014 84
B 050
B 140
037 875 84
037 892 84
037 863 84
037 889 84
B 140
038 006 84
038 004 84
Motor type
14
one speed
D/Y
Switch-off in
44
DC circuit
Switching
element
Contact
ZBF
B 050
B 140
one speed
Y/YY
037 897 84
037 899 84
214228k4.p65/121201
1)
Contact
one speed
Y/YY
020 323 84
02032384.eps
D
for low speed
YY for high speed
Switch-over to high speed winding via external
supply switch-over and jumper.
02032884.eps
020 328 84
1U, 1V, 1W
2U, 2V, 2W
214228k5.p65/121201
020 332 84
02033284.eps
45
YY low voltage
Y
high voltage
For inverter operation, connect motor with YY or Y
connection according to inverter settings.
020 337 84
02033784.eps
1U, 1V, 1W
2U, 2V, 2W
028 857 84
02885784.eps
Y high voltage
D low voltage
Brake coil rated for the low voltage.
46 037 857 84
214228k5.p65/121201
03785784.eps
Y high voltage
D low voltage
Brake coil rated for the
low voltage.
03785884.eps
037 858 84
( 1: 3 )
Y high voltage
D low voltage
Brake coil rated for the low voltage.
03785984.eps
214228k5.p65/121201
037 859 84
47
03786084.eps
037 860 84
= Intermediate terminal
03786144.eps
48 037 861 84
214228k5.p65/121201
1U, 1V, 1W
2U, 2V, 2W
03786244.eps
037 862 84
high voltage
214228k5.p65/121201
03786344.eps
037 863 84
49
YY low voltage
Y
high voltage
= Intermediate terminal
03786484.eps
037 864 84
Y high voltage
D low voltage
03786584.eps
50 037 865 84
214228k5.p65/121201
D
for low speed
YY for high speed
Switch-over to high speed winding via external
supply switch-over and jumper.
03787184.eps
037 871 84
214228k5.p65/121201
037 872 84
51
= Intermediate terminal
03787384.eps
Motor winding connected as in connection diagram (1U and 2U connected to one terminal).
Brake connected to terminals 1 and 2 of the GP module.
SE module connected to terminals 3 and 4 of the GP module.
SE module connected with intermediate terminal A and the motor winding via terminal 1U 2U.
GP module connected with the motor winding and intermediate terminal A as in the connection diagram.
037 873 84
52 037 875 84
214228k5.p65/121201
03787584.eps
Y high voltage
D low voltage
Voltage-dependent switch-off in the DC circuit
03787644.eps
037 876 84
D
for low speed
YY for high speed
03788084.eps
214228k5.p65/121201
037 880 84
53
YY low voltage
Y
high voltage
Voltage-dependent switch-off in the DC circuit
03788184.eps
Important: The brake will not function without a separate power supply to
terminals 5 and 6 of the GE module.
037 881 84
03788284.eps
54 037 882 84
214228k5.p65/121201
Y high voltage
D low voltage
Brake coil rated for the low voltage.
03788384.eps
037 883 84
Y high voltage
D low voltage
03788484.eps
214228k5.p65/121201
037 884 84
55
D
for low speed
YY for high speed
03788584.eps
037 885 84
03788684.eps
Separate power
supply to the brake: GS module not connected to the motor winding.
Power supply by the customer according to variant B.
56 037 886 84
214228k5.p65/121201
= Intermediate terminal
03788784.eps
037 887 84
03788884.eps
214228k5.p65/121201
037 888 84
57
high voltage
03788984.eps
037 889 84
YY low voltage
Y high voltage
03789084.eps
58 037 890 84
= Intermediate terminal
214228k5.p65/121201
D
for low speed
YY for high speed
03789184.eps
037 891 84
03789284.eps
214228k5.p65/121201
037 892 84
59
Y high voltage
D low voltage
Separate power supply to brake
For inverter operation, connect motor with Y or D
connection according to inverter settings.
03789384.eps
037 893 84
03789484.eps
60 037 894 84
214228k5.p65/121201
D
for low speed
YY for high speed
03789584.eps
037 895 84
YY low voltage
Y high voltage
214228k5.p65/121201
Important: The brake will not function without a separate power supply to
terminals 5 and 6 of the GS module.
037 896 84
03789684.eps
61
Y high voltage
D low voltage
Separate DC supply to brake
For inverter operation, connect motor with Y or D
connection according to inverter settings.
03789784.eps
037 897 84
03789884.eps
62 037 898 84
214228k5.p65/121201
YY low voltage
Y high voltage
03789984.eps
037 899 84
214228k5.p65/121201
03800184.eps
Separate power
supply to the brake: GS module not connected to the motor winding.
Power supply by the customer according to variant B.
038 001 84
63
= Intermediate terminal
03800284.eps
Motor winding connected as in connection diagram (1U and 2U connected to one terminal).
Brake connected to terminals 1 and 2 of the GS module.
SE module connected to terminals 3 and 4 of the GS module.
SE module connected with the motor winding via intermediate terminal A and terminal 1U 2U.
Important: The brake will not function without a separate power supply to terminals 5, 6
and 7 of the GS module.
038 002 84
03800384.eps
64 038 003 84
214228k5.p65/121201
high voltage
03800484.eps
038 004 84
YY low voltage
Y high voltage
214228k5.p65/121201
= Intermediate terminal
03800584.eps
038 005 84
65
03800684.eps
038 006 84
Y high voltage
D low voltage
Separate power supply to brake
For inverter operation, connect motor with Y or D
connection according to inverter settings.
03800784.eps
66 038 007 84
214228k5.p65/121201
03800884.eps
038 008 84
YY low voltage
Y high voltage
03801484.eps
214228k5.p65/121201
Important: The brake will not function without a separate power supply to
terminals 5, 6 and 7 of the GS module.
038 014 84
67
D
for low speed
YY for high speed
03801584.eps
038 015 84
D
for low speed
YY for high speed
03801684.eps
Important: The brake will not function without a separate power supply to
terminals 5, 6 and 7 of the GS module.
68 038 016 84
214228k5.p65/121201
03801784.eps
Separate power
supply to the brake:
038 017 84
= Intermediate terminal
03801884.eps
214228k5.p65/121201
038 018 84
69
03802084.eps
038 020 84
= Intermediate terminal
03802184.eps
Motor winding connected as in connection diagram (1U and 2U connected to one terminal).
Brake connected to terminals 1 and 2 of the GE module.
SE module connected to terminals 3 and 4 of the GE module.
SE module connected to the motor winding via intermediate terminal A and terminal 1U 2U.
GE module connected with the motor winding via intermediate terminal A and terminal 2V.
70 038 021 84
214228k5.p65/121201
YY low voltage
Y
high voltage
A: Common power supply to motor and brake.
Brake coil only rated for the high voltage.
038 186 84
YY low voltage
Y
high voltage
03818784.eps
= Intermediate terminal
214228k5.p65/121201
038 187 84
71
= Intermediate terminal
03833784.eps
038 337 84
2U, 2V, 2W
= Intermediate terminal
03833784.eps
Motor winding connected as in connection diagram (1U and 2U connected to one terminal).
Brake connected to terminals 1 and 2 of the GF module.
GF module connected with the motor winding and intermediate terminal A as in the connection
diagram.
72 038 338 84
214228k5.p65/121201
N0
1U, 1V, 1W
2U, 2V, 2W
1U
1V
1W
2U
2W
2V
401 402
1L1*
1L1
1L2*
2U
1U
2V
2W
N10
1V
1W
N0
1L2
1L3
1L3*
GP
~ ~ ~
6
N10 N0
2U
1U
402 401
03842084.eps
038 420 84
N10
1U, 1V, 1W
2U, 2V, 2W
1U
1V
1W
2U
2W
2V
401 402
1L2* 1L3*
2U
1U
2V
1V
2W
1W
N0
1L2
GP
SE
N10
~ ~ ~
~ ~
BK
A
1L1
WH
BK
GY
WH
2U
1U
1L3
1L1*
N10 N0
GP
GY
402 401
SE
03842184.eps
214228k5.p65/121201
Motor winding connected as in connection diagram (1U and 2U connected to one terminal).
Brake connected to terminals 1 and 2 of the GP module.
SE module connected to terminals 3 and 4 of the GP module.
SE module connected to the motor winding via intermediate terminal A
and terminal 1U 2U.
GP module connected with the motor winding and intermediate terminal A as in the connection
diagram.
038 421 84
73
N10
1U, 1V, 1W
2U, 2V, 2W
1U
1W
1V
2U
2W
2V
401 402
1L2* 1L3*
2U
1U
2V
1V
2W
1W
1L2
GP
SE
N10
~ ~ ~
~ ~
N0
BK
A
1L1
WH
BK
GY
WH
2U
1U
1L3
N10 N0
1L1*
+
1
GY
402 401
SE
GP
03842184.eps
Motor winding connected as in connection diagram (1U and 2U connected to one terminal).
Brake connected to terminals 1 and 2 of the GP module.
SE module connected to terminals 3 and 4 of the GP module.
SE module connected to the motor winding via intermediate terminal A and terminal 1U 2U.
GP module connected with the motor winding and intermediate terminal A as in the connection
diagram.
038 421 84
2U, 2V, 2W
N10
N0
1V
1W
2U
2W
2V
401 402
2U
1U
1L2
1L3
2V
2W
1V
1W
N0
GE
SE
N10
~ ~
~ ~
BK
BK WH GY
N10
2U
1U
= Intermediate terminal
WH GY
1L1
4
GE
402 401
SE
03842284.eps
Motor winding connected as in connection diagram (1U and 2U connected to one terminal).
Brake connected to terminals 1 and 2 of the GE module.
SE module connected to terminals 3 and 4 of the GE module.
SE module connected with intermediate terminal A and with the motor winding via terminal 1U 2U.
GE module connected to the motor winding via intermediate terminal A and terminal N10.
74 038 422 84
214228k5.p65/121201
N10
N0
1U, 1V, 1W
2U, 2V, 2W
1U
1W
1V
2U
2V
2W
401
402
1L2* 1L3*
2U
1U
2V
2W
N10
1V
1W
N0
1L1 1L2
1L1*
1L3
GF
6
N0 N10
1U
2U
402 401
= Intermediate terminal
03842384.eps
038 423 84
2U, 2V, 2W
N10
N0
1U
1V
1W
2U
2V
1L2
1L3
2U
1U
2V
2W
N10
1V
1W
N0
1L1
2W
401 402
GF
7
N10
1U
2U
= Intermediate terminal
402 401
03842484.eps
214228k5.p65/121201
038 424 84
75
1U, 1V, 1W
2U, 2V, 2W
N0
N10
1W
1V
2U
2V
2W
401
402
1L1*
1L1
1L2*
2U
1U
2V
1L3*
2W
GE
N10
~ ~
1V
1W
1L2
1L3
N0
2L2 2L1
402 401
03842584.eps
038 425 84
N10
N0
1W
1V
2U
2V
2W
401
402
1L1*
1L1
2U
1U
1L2*
1L3*
2V
2W
1V
1W
1L2
1L3
GS
N10
N0
~ ~
7
2L2 2L1
402 401
03842684.eps
Motor winding connected as in connection diagram (1U and 2U connected to one terminal).
Brake connected to terminals 1 and 2 of the GS module.
Jumper between terminals 3 and 4 of the GS module.
Important: The brake will not function without a separate power supply to terminals 5 and 6
of the GS module.
76 038 426 84
214228k5.p65/121201
N0
N10
1U
1W
2V
2U
2V
2W
401
402
1L1*
1L1
1L2*
2U
1U
2V
1L3*
2W
1W
1L2
1L3
GS
N10
~ ~ ~
1V
N0
402 401
03842784.eps
038 427 84
N10
U
1U
1V
1W
2U
1L1*
1L1 1L2*
2U
1U
2V
2W
401
402
401
402
401
402
L+
L-
1L3*
2V
2W
N10
1V
1W
N0
1L2
1L3
03842884.eps
214228k5.p65/121201
038 428 84
77
1U, 1V, 1W
2U, 2V, 2W
N10
1V
1W
2U
401 402
2W
2V
1L2* 1L3*
2U
1U
2V
1V
2W
1W
BK
BK
- +
~ ~
~ ~
N0
WH GY
2U
1U
A
1L1 1L2
GE
SE
N10
WH
1L3
2L2 2L1
1L1*
= Intermediate terminal
GY
402 401
GE
SE
03842984.eps
Motor winding connected as in connection diagram (1U and 2U connected to one terminal).
Brake connected to terminals 1 and 2 of the GE module.
SE module connected to terminals 3 and 4 of the GE module.
SE module connected with the motor winding via intermediate terminal A and terminal 1U 2U.
Important: The brake will not function without a separate power supply to terminals 5 and 6 of
the GE module.
038 429 84
N10
1U, 1V, 1W
2U, 2V, 2W
1V
1W
2U
2W
2V
401 402
1L1*
1L1 1L2* 1L3*
2U
1U
2V
1V
2W
1W
N10
GE
VE
- +
N0
WH
BU
RD
~ ~
7
4
WH
1L2
1L3
2L2 2L1
4
GE
BU
RD
402 401
VE
03843084.eps
Motor winding connected as in connection diagram (1U and 2U connected to one terminal).
Brake connected to terminals 1 and 2 of the GE module.
VE module connected to terminals 1, 3 und 4 of the GE module.
Important: The brake will not function without a separate power supply to terminals 5 and 6 of
the GE module.
78 038 430 84
214228k5.p65/121201
N10
1W
1V
2U
401 402
2W
2V
1L2* 1L3*
2U
1U
2V
2W
N10
1V
1W
N0
GS
SE
~ ~
BK
BK
- +
~ ~
7
WH GY
2U
1U
4
WH
GY
2L2 2L1
= Intermediate terminal
402 401
GS
SE
03843184.eps
Motor winding connected as in connection diagram (1U and 2U connected to one terminal).
Brake connected to terminals 1 and 2 of the GS module.
SE module connected to terminals 3 and 4 of the GS module.
SE module connected to the motor winding via intermediate terminal A and terminal 1U 2U.
Important: The brake will not function without a separate power supply to terminals 5 and 6 of
the GS module.
038 431 84
N10
1V
1W
2U
2W
2V
401 402
1L1*
1L1 1L2* 1L3*
2U
1U
2V
1V
2W
1W
N10
GS
VE
- +
N0
WH
BU
RD
~ ~
7
4
WH
2L2 2L1
1L2 1L3
4
GS
1
RD
BU
402 401
VE
03843284.eps
214228k5.p65/121201
Motor winding connected as in connection diagram (1U and 2U connected to one terminal).
Brake connected to terminals 1 and 2 of the GS module.
VE module connected to terminals 1, 3 and 4 of the GS module.
Important: The brake will not function without a separate power supply to terminals 5 and 6 of
the GS module.
038 432 84
79
N10
1W
1V
2U
401 402
2W
2V
1L2* 1L3*
2U
1U
2V
1V
2W
1W
N0
GS
SE
N10
~ ~
BK
BK
- +
~ ~ ~
WH GY
2U
1U
WH
GS
GY
= Intermediate terminal
402 401
SE
03843384.eps
Motor winding connected as in connection diagram (1U and 2U connected to one terminal).
Brake connected to terminals 1 and 2 of the GS module.
SE module connected to terminals 3 and 4 of the GS module.
SE module connected to the motor winding via intermediate terminal A and terminal 1U 2U.
Important: The brake will not function without a separate power supply to terminals 5, 6 and 7 of
the GS module.
038 433 84
1U, 1V, 1W
2U, 2V, 2W
N10
N0
1V
1W
2U
2W
2V
401 402
1L1*
1L1 1L2* 1L3*
2U
1U
2V
1V
2W
1W
N10
GS
VE
- +
N0
WH
BU
RD
~ ~ ~
7
4
WH
1L2
1L3
GS
1
RD
BU
402 401
VE
03843484.eps
Motor winding connected as in connection diagram (1U and 2U connected to one terminal).
Brake connected to terminals 1 and 2 of the GS module.
VE module connected to terminals 1, 3 and 4 of the GS module.
Important: The brake will not function without a separate power supply to terminals 5, 6 and 7 of
the GS module.
80 038 434 84
214228k5.p65/121201
1U
1U, 1V, 1W
2U, 2V, 2W
N10
1W
1V
2U
2V
1L1*
1L1
1L2*
2U
1U
2V
2W
N10
1V
1W
N0
1L2
1L3
2W
1L3*
03843584.eps
214228k5.p65/121201
038 435 84
81
Depending on the motor features, the connections for temperature monitoring and/or
brake monitoring are brought out on Euro terminals in the terminal box.
Important: PTC thermistors to DIN 44081 are suitable for tripping devices with
2,5 V DC output voltage and 4 kW tripping resistance.
PTC thermistors may only be continuity tested with max. 2,5 V DC.
Do not use a buzzer (voltage peaks) or similar devices. The resistance
of one PTC thermistor is 20 ... 250 W at temperatures of 20 C to
JTNF 20K. (TNF = rated operating temperature).
Temperature detector (bimetallic switch):
601 602
Brake monitoring
Release monitoring:
PTC thermistor
PTC thermistor
PTC thermistor
PTC thermistorr
3x
3x
3x
6x
Switch-off
101 102
P1 P2
Switch-off 1
Warning
101 102
P1 P2
111 112
P11 P12
101 102
P1 P2
Switch-off
3x
Switch-off 2
03781944.eps
PTC thermistor
201 202
P21 P22
03782044.eps
Brake monitoring
Release monitoring
03782144.eps
Brake monitoring
Adjustment monitoring
03782344.eps
Temperature detector
Warning
wh gn bn
801 802 803
111 112
P11 P12
82
03782744.eps
03781644.eps
wh gn bn
804 805 806
03781744.eps
601
P1
602
P2
03782244.eps
214228k6.p65/121201
6x
Technical data
Z range
Transport temperature
- 20 ... + 40C
Storage temperature
0 ... + 40C
Storage conditions
dry, indoors
- 20 ... + 40C
Environment
acid-free
Coolant
A ir
Coolant temperature
max. + 40C
105K
Altitude
Air circuit
Type of enclosure
Mounting arrangement
IP 54
500 V / 50 Hz
low vibration
150 mm at rear
400 V / 50 Hz
480 V / 60 Hz
Voltage tolerance
500 V / 50 Hz
Motor size
ZBF 63 132
3600
ZNA 63 100
5000
ZNA 63 100
5000
4000
4000
3600
3600
3000
3000
ZBA 63 100
5000
4000
3600
3000
ZBA 63 132
3600
ZBA 160 180 A, with B 140 brake
ZBA 160 180 A, with B 280 brake
2000
214228k6.p65/121201
83
Troubleshooting
Item Problem
1
Possible cause
Solution
Replace fuse.
Check connections.
Control defective.
Eliminate fault.
Winding defective.
Eliminate short-circuit.
Correct connection.
Overload.
Voltage drop.
Overload.
Insufficient cooling.
10
11
84
Excessive noise
Correct connection.
Replace fuse.
214228k6.p65/121201
IP:
3 ~
kg
Bremse:
ANR:
Nm
FI: --1/min
V
V
AC
V
Hz
Made in Germany
EN 60034-1
Iso : F
%ED
cos
Installation
designation:
kW
c/h
A
A
V
DC
ASN:
---
C
A
EFF.
41806644.eps
Demag
Made in Germany
Cranes & Components GmbH EN 60034-1
Typ:
Mot.Nr.:
3~
Iso.: F
kW cos :
1/min ----
c/h ----
V
V
Bremse:
AC
V DC
kg
ANR:
ASN:
IP:
%ED
Hz
C
A
A
A
FI: --EFF.
41806744.eps
Type:
Mot.Nr:
3 ~ IP
kg
Nm
Bremse:
ANR:
Fl:
Hz
1/min
V
V
AC
V DC
ASN:
EN 60034-1
Iso.: F
%ED
kW
cos :
C
c/h
A
A
V
A
EFF.
Made in Germany
214228k6.p65/121201
42002644.eps
85
86
214228k6.p65/121201
Notes
1 page(s) Page 1
EC conformity declaration
Demag AC motor type Z, M
Ident. no.
205 211 44
Issue 0899
EN
Hereby we,
Demag AC motor
of the
Z, M
type of serial design, with or without the relevant gearbox, has been declared in
conformity with the provisions of the following relevant regulations:
EC EMC Directive
89/336/EEC
amended by
93/68/EEC
Electromagnetic compatibility
EN 50082-2
Electromagnetic compatibility
EN 60034
EN 60034-1
EN 60034-5
EN 60034-7
EN 60034-8
EN 60034-9
Noise limits
EN 60034-14
EN 60034-18-1
EN 60529
214228k6.p65/121201
# = Modifications compared
to previous issue
i.V. Ropelius
ppa. Peters
Vertrieb
Motoren
Antriebstechnik
Normung
Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, D-58286 Wetter
Class. no.
715 IS 919
Not liable for errors or omissions. Subject to change.
87
88
Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, D-58286 Wetter