DEMAG Z Motor Manual

Operating instructions
Motors, Z motor range
41807744.eps
121201 EN 214 228 44 720 IS 919

Manufacturer Demag Cranes & Components GmbH
Drives
P.O. Box 67 · D-58286 Wetter
Telephone (+49/2335) 92-0 · Telefax (+49/2335) 927298
Internet http://www.drives.demagcranes.de
E-mail: [email protected]
Other documents For geared motors also refer to the gearbox operating instructions.
Document Part no.
DE EN FR ES
Geared motors for general applications – with prices 203 150 44 –
Geared motors for general applications – with prices – 203 251 44 – 203 251 44
Geared motors for travel drive applications – Volume 2 203 355 44 –
Geared motors for travel drive applications – Volume 2 – 203 357 44 – 203 357 44
Geared motors for travel drive applications – with prices 223 105 44 223 106 44 223 107 44 223 108 44
Geared travel motors – Volume 3 – Quick selection and gearbox limit torque 203 013 44 –
Geared travel motors – Volume 3 – Quick selection and gearbox limit torque – 203 014 44 – 203 014 44
Demag Indrive variable speed geared motors – with prices 203 390 44 –
Demag Indrive variable speed geared motors – with prices – 203 392 44 – 203 392 44
Helical gearbox operating instructions

214 150 44 214 151 44 214 152 44 214 153 44
D gearbox range
Angular gearbox operating instructions
214 057 44 214 058 44 214 059 44 214 060 44
W gearbox range
Offset gearbox operating instructions
214 205 44 214 206 44 214 207 44 214 208 44
A gearbox range
Operating instructions additional equipment for brakes
214 040 44 – – 214 043 44
Z motor range
Operating instructions
214 021 44 – – –
Plug connection for KB and Z motors – new design
Motor component parts

Z motor range
• Frame sizes 63 and 71 222 856 44 222 857 44 222 858 44 222 859 44
• Frame sizes 80 and 90 A 222 864 44 222 865 44 222 866 44 222 867 44
• Frame sizes 90 B and 100 222 876 44 222 877 44 222 878 44 222 879 44
• Frame sizes 112 A and 132 222 884 44 222 885 44 222 886 44 222 887 44
• Frame sizes 160 and 180 A 222 892 44 222 893 44 222 894 44 222 895 44
• Frame sizes 180 B and 200 222 896 44 222 897 44 222 898 44 222 899 44
• Frame size 225 222 900 44 222 901 44 222 902 44 222 903 44
Contents 0 Foreword 4
0.1 Copyright 4
0.2 After-sales service 4
0.3 Guarantee 4
0.4 Limitations of liability 5
0.5 Definitions 5
1 Safety 6
214228k1.p65/121201
1.1 Symbols 6
1.2 Intended use 6
1.3 Prohibited practises, improper use 6
1.4 Safety instructions 7
2
2 Receiving, transport and storage 8
2.1 Receiving 8
2.2 Transport 8
2.3 Storage 8
3 Product description 9
3.1 Motor 9
3.1.1 Motor type designation 9
3.1.2 Rating plates 10
3.2 ZB. motor brake 12
4 Installation 13
4.1 Checking the condition of the motor 13
4.2 Checking the installation site 13
4.3 Motor mounting position 13
4.4 Special instructions for installing the motor 13
4.5 Requirements for connecting the motor 13
5 Commissioning 14
5.1 Requirements 14
5.2 Check when commissioning 14
5.3 Geared motors 14
6 Maintenance 15
6.1 Checking before and during operation 15
6.2 Maintenance schedule 15
6.3 B003 – B680 brakes 16
6.3.1 Checking and adjusting the brake air gap s1 17
6.3.2 Replacing the brake disk 20
6.3.3 Tightening torques of bolts 28
6.4 Options 28
6.4.1 Sealing of B 004 – B 680 brakes, IP55 29
6.4.2 Reduced noise level 29
6.4.3 Manual brake release unit 29
6.4.4 Micro-switches 29
7 Motor/brake connection diagrams 30
7.1 Brake control 30
7.2 Brake operating times 35
7.2.1 ZBA range brake operating times 35
7.2.2 ZBF range brake operating times 36
7.2.3 Brake power consumption 36
7.3 Selection criteria 37
7.4 Z motors standard connection diagrams to EN standards 38
7.4.1 ZBF travel motors 38
7.4.2 ZBA standard motors with brake 38
7.4.3 ZNA standard motors without brake 39
7.5 Connection diagram selection 40
7.5.1 Line operation 40
7.5.2 Inverter operation 44
7.6 Connection diagrams 45
7.7 Connecting temperature and brake monitoring devices 82
8 Technical data 83
9 Troubleshooting 84
10 Forms for documenting the installation, rating plate 85
EC conformity declaration 87
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3
0 Foreword
You have purchased a Demag product. This equipment was manufactured in ac-
cordance 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 opera-
tion of our products.
0.1 Copyright These operating instructions must be treated confidentially. They should only be
used by authorized personnel. They may only be entrusted or made available to
third parties with the prior written consent of Demag. All documents are protected
within the sense of copyright law.
No part of this documentation may be reproduced, utilized or transmitted without

specific prior consent. Infringements are an offence resulting in obligatory compen-
satory damages. All industrial rights reserved.
0.2 After-sales service For technical information on Demag products and their systematic application,
please refer to one of our after-sales service stations, the relevant representative or
to our main office in Wetter.
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,
• refurbishment or modification of the product unless approved in writing by
Demag.
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0.4 Limitations of liability All technical information, data and instructions for operation contained in these op-
erating 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 fur-
ther development of the hoist units which are the subject of these operating instruc-
tions. 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 sup-
plied 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 origi-
nal 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 legis-
lation.
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 rele-
vant 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 incor-
rect 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.
• Experienced technician
Experienced technicians are defined as persons, who, owing to their technical
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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.
5
1 Safety
1.1 Symbols The following symbols and recommendations indicate potential safety hazards or
causes of damage or provide useful information.
Hazard warning
This symbol appears in the operating instructions next to all instructions relating to
safety at work wherever a potential hazard to life and limb exists if the instructions
are not complied with.
Follow these instructions at all times and be particularly careful and cautious.
Pass on safety instructions to all persons entrusted with working on motors includ-
ing the power supply.
In addition to the safety instructions, observe all general safety regulations and
codes of practise at all times.
Warning against electrical hazards

Contact with live parts can result in immediate death. Protective covers (e.g. covers
and enclosures) marked with this sign may only be opened by qualified electricians.
Before opening, all relevant operating, control, feed or other voltages must be dis-
connected.
Operating hazard for the installation

This symbol in the operating instructions indicates all warnings which, if not com-
plied with, may result in damage to motors.
1.2 Intended use 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).
1.3 Prohibited practises, Under certain conditions, operation of standard motors is prohibited as this could
result in malfunctions, faults in the equipment or hazard to life and limb, e.g.:
improper use
• Acidic, corrosive air as coolant
• Operation outside the permitted temperature range
• Operation beyond the normal air pressure. Otherwise, power adjustments are
necessary
• Operation under conditions of high humidity or splashwater
• Manipulation of electrical modules
Safety devices must not be rendered inoperable or modified or used in any way
other than that for which they have been designed.
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6
1.4 Safety The relevant national accident prevention regulations and the general safety condi-
tions must always be observed when our products are operated in order to avoid
instructions accidents and damage to machinery. If the safety instructions given in these operat-
ing instructions are not observed in any way, personal injury or even death can re-
sult.
Dangerous voltage!
Motors are connected to a mains power supply. Any contact with live parts can lead
to very serious injury or even death.
Putting motors into operation 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 ad-
versely affect your ability to react,
• if the general accident prevention, operating and installation regulations (e.g. DIN-
VDE 0100/0113/0160) have been observed.
Additional safety instructions Only carry out maintenance and installation work
• if you are qualified specialist personnel,
• if the motors are at zero voltage,
• if no hazard exists (e.g. crushing hazard, slipping hazard, etc.),
• if the motors are secured against restoration of the power supply,
• if all cables and motor terminals are at zero potential (establish with a voltmeter),
• with insulated tools,
• using genuine spare parts.
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7
2 Receiving, transport and storage
2.1 Receiving The scope of delivery is specified in the shipping papers. Check the delivery imme-
diately 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 contractor’s 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 pack-
aging guidelines of Demag Cranes & Components.
Symbols used on the packing
This way up Fragile Keep dry Protect from heat
Top-heavy No hooks Attach sling here 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 Motors must be stored as follows:

• in dry places with low temperature fluctuations
• in the same position as for operation
• protected against dust and moisture
• on a wooden support
• free from vibration (no impacts)
Drives must not be stacked on top of each other.
Unless otherwise agreed in the purchase contract, standard conservation is guaran-

teed 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 mo-
tors are to be stored for periods of longer than 6 months.
Important! Motors may otherwise be damaged.
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3 Product description
3.1 Motor 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.
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.
3.1.1 Motor type designation
Brake size
B003, B004, B007, B020, B050, B140, B280, B680
Z B A 100 A 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
Z Cylindrical rotor motor
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3.1.2 Rating plates Rating plate for Z..63 A to Z..71 B motors with/without brake
The rating plate is arranged on the left or right of the terminal box on the motor
end cap, e.g.
1 Demag Cranes & Components GmbH Made in Germany

EN 60034-1
2 Typ: ZBA 71 B 4 B007 3 ~ IP: 54 Iso : F IM B5-1
3 Mot.Nr .: 71740301 100 %ED 0,37 kW
4 10,0 kg FI: --- 50 Hz cos ϕ 0,60
5 1380 1/min c/h --- ˚C
6 230 V 2,50 A
400 V 1,40 A
7 Bremse: 5,1 Nm AC 400 V DC 180 V 0,14 A
8 ANR: 85674100 ASN: 00201 EFF.
41806344.eps
1 Manufacturer, country of origin, regulations
2 Type designation, no. of phases, enclosure, temperature class, model
3 Motor number, power, duty factor
4 Motor weight, inertia factor, frequency, power factor
5 Speed, switching frequency, ambient temperature > 40 °C
6 Connection, voltage, current
7 Brake: brake torque, supply voltage, coil voltage, coil current
8 Order number, entry number
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10
Rating plate for Z.. 80 A to Z.. 132 C motors with/without brake
The rating plate is attached to the right or left of the terminal box base, e.g.
1 Demag Made in Germany

Cranes & Components GmbH EN 60034-1
2 Typ: ZBA 80 A 8 B007 3~ IP: 54
3 Mot.Nr.:71739107 Iso.: F 100 %ED
4 0,18 kW cosϕ : 0,57 50 Hz
5
670 1/min ---- c/h ---- ˚C
6 ∆ 230 V 1,70 A
Y 400 V 0,95 A
7 Bremse: 5,1 Nm AC 400 V DC 180 V 0,14 A
8 IM B5 - 1 16,0 kg FI: ---
9 ANR: 85674300 ASN: 00401 EFF.
41806444.eps
2 Type designation, no. of phases, enclosure
3 Motor number, temperature class, duty factor
4 Power, power factor, frequency
5 Speed, switching frequency, ambient temperature > 40 °C
8 Model, motor weight, inertia factor
9 Order number, entry number
Rating plate for Z.. 160 A to Z.. 225 B motors with/without brake
The rating plate is attached to the left or right next to the terminal box on the stator,
e.g.
1 Demag Cranes & Components GmbH EN 60034-1

2 Type: ZBA 160 B4 B280 3 ~ IP 54 Iso.: F IM B3-1
Mot.Nr: 12345678 100 %ED 15,0 kW
Made in Germany
3
4 183 kg Fl: 50 Hz cos ϕ : 0,84
5 1440 1/min c/h 40 ˚C
∆ 230 V 51,00 A
6
Y 400 V 29,0 A
7 Bremse: 187 Nm AC 400 V DC 180 V 0,45 A
8 ANR: 59021500 ASN:19301 EFF.
41965544.eps
2 Type designation, no. of phases, enclosure, temperature class, model
3 Motor number, power, duty factor
4 Motor weight, inertia factor, frequency, power factor
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5 Speed, switching frequency, ambient temperature

8 Order number, entry number 11
3.2 ZB. Motor brake Demag B003 to B680 disk brakes are spring-actuated brakes featuring electromag-
netic brake release. The brake fitted under the fan cover can be controlled inde-
pendently 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-actu-
ated 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.
B 003 DC brake B004 – B 680 DC brakes
1 2 18 4 16 6 7 15 8
17 12 14
1 Motor end cap 7 Magnet assembly 13 Sealing washer

2 Engaging stirrup 8 Radial shaft sealing ring 14 Adjusting nut
3 Cover tape 9 Friction plate 15 Brake spring
4 Brake disk 10 Sleeve 16 Armature disk
5 Friction plate 11 Grub screw 17 Collared pin
6 Stop plate 12 Distance spring 18 Friction plate, stainless steel, (for ZBA
motors with brakes B 004 – B 050)
42282444.eps 41687356.eps
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4 Installation
4.1 Checking the Before installing the motor, check whether it has suffered any damage during trans-
portation or while in storage, such as corrosion, leaks, deformation or breakage.
condition of the
Do not clean drives with compressed air!
motor
4.2 Checking the 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
installation site plate, the motors must only be operated with special equipment or features (see
rating plate).
Ambient temperature: from –10 °C to +40 °C
Installation height: 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 in-
ducted again immediately,
• no residue from operating processes can accumulate on the motor, fall be-
tween the drive elements or damage the sealing ring,
• the rating plate is accessible.
4.3 Motor mounting Before installing the motor, check that it will be operated in the mounting position
specified on the rating plate.
position
4.4 Special instructions for If the motor is operated outdoors in vertical mounting position IM V1 or in an in-
clined mounting position with the shaft facing downwards, it should be protected by
installing the motor 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.
4.5 Requirements for • You must be a trained electrician and familiar with the relevant accident preven-
tion regulations and codes of practise.
connecting the motor
• 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” .
Connecting pin threads in terminal box
Motor frame size Pins
63, 71, 80, 90 A M4
90 B, 100 M5
112, 132, 160, 180 A M6
180 B, 200, 225 M8
To change the direction of rotation of the motor, two of the three phase conductors
must be interchanged.
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The instructions contained in section 5 “Commissioning” must be followed!
13
5 Commissioning
5.1 Requirements Before the drive unit is put into service:

• the terminal box be must be closed,
• the fan cover must be fitted (as supplied),
• the line voltage and frequency specified on the rating plate must match the given
power supply,
• the motor and brake must be checked for correct connection (check direction of
rotation),
• heat must be able to dissipate (e.g. air vent slits must be free),
• it must be ensured that the drive unit does not constitute a hazard (e.g. no haz-
ards caused by rotating or live parts),
• it must be ensured that there are no other hazard sources.
Check that:
5.2 Check when • the motor runs correctly (e.g. no speed fluctuations or excessive noise),
commissioning • there is no extreme vibration.
5.3 Geared motors For geared motors also refer to the gearbox operating instructions.
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6 Maintenance
6.1 Checking before and 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
during operation has been eliminated.
Check the motor for: Check Action

• External damage ® Inform person responsible
• Unusual noises during operation ® Inform person responsible
• Dirt accumulation ® Remove dirt
6.2 Maintenance schedule
Maintenance schedule
Interval Part Maintenance See section
In accordance with the Brake Check brake of motors fitted with brake 6.3.1 and 6.3.2
operating conditions, at least
every 3000 hours of
operation.
Every 10 000 hours of Motor Inspect the motor and clean the cooling air channels
operation.
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15
6.3 B003 – B680 brakes The following work may only be carried out by qualified personnel.
Observe relevant safety regulations and codes of practise and the instructions con-
tained in the “Safety instructions” section.
Options: • Sealing (covering tape) for brake types B004 – B680

(standard for B003 brakes)
• Reduced noise level (standard for B 050 – B 680 brakes)
• Manual brake release unit
• Micro-switch for brake monitoring
See 6.4 “Options” .
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 cer-
tain intervals and to adjust it as necessary to ensure the brake releases reliably.
Brake size B 003 B 004 B 007 B 020 B 050 B 140 B 280 B 680
Motor ZBA
Brake air gap s 1 min 0,3 0,3 0,3 0,3 0,3 0,35 0,4 0,4
Brake air gap s 1 max 1,0 0,65 0,65 0,65 0,65 1,3 1,3 1,3
Motor ZBF
Brake air gap s 1 min 0,3 0,3 – 0,3 0,3 0,35 – –

Brake air gap s 1 max 1,2 1,2 – 1,2 1,2 1,2 – –
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.
Brake size B 003 B 004 B 00 7 B 020 B 050 B 140 B 280 B 680
Motor Brake work until readjustment WN in Ws
ZBA 160 · 10 6 100 · 10 6 100 · 10 6 120 · 10 6 200 · 10 6 1000 · 10 6 1500 · 10 6 2500 · 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.
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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 replace-
ment. In addition to the brake disk and the required small parts, the set also includes
the assembly instructions.
16
For a general overhaul, overhaul sets and wear part sets are available
ZBA motors
Overhaul set
Brake size ZBA 63 ZBA 80 ZBA 90B ZBA 112A ZBA 160 ZBA 180B ZBA 225 Wear part set
ZBA 71 ZBA 9 0 A ZBA 100 ZBA 132 ZBA 180A ZBA 200
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 Wear part set
ZBF 63/71 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
Undo the four screws and remove the fan cover.
41431944.eps 41432044.eps
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Remove the retaining ring and fan.
41432144.eps 41432244.eps 17
Checking the remaining thickness of the brake disk
Brake size B004 B007 B020 B050 B140 B280 B680
Remaing thickness b min 5 5 6 7 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.
Remaining thickness bmin
For a visual check, push covering tape (12) to the side

using a screwdriver.
41777744.eps 42028944.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)
End cap (6)

214228k3.p65/121201
Stop plate (1)
Friction disk (2)

18 41777344.eps 42029146.eps
B004-B680 brakes
Checking/adjusting the brake air gap
Brake size B 004 B 007 B 020 B 050 B 140 B 280 B 680
Motor ZBA
Brake air gap s 1 min 0,3 0,3 0,3 0,3 0,35 0,4 0,4
Brake air gap s 1 max 0,65 0,65 0,65 0,65 1,3 1,3 1,3
Motor ZBF
Brake air gap s 1 min 0,3 – 0,3 0,3 0,35 – –
Brake air gap s 1 max 1,2 – 1,2 1,2 1,2 – –
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 B050 B140 B280 B680

Motor ZBA
Adjusting angle a 1 120° 120° 120° 90° 80° 70° 60°
Motor ZBF
Adjusting angle a 1 120° - 120° 90° 80° - -
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
Magnet assembly (9) Magnet assembly (9)
Feeler gauge Feeler gauge
Brake disk (3) Brake disk (3)
Friction plate (14) Retaining plate for sealing tape (7) – only for IP55
End cap (6) End cap (6)
Stop plate (1) Stop plate (1)
Armature disk (2) Armature disk (2)
42288944.eps 42288844.eps 42029144.eps
ZBA motor ZBF motor

B140 – B680 brakes Damping plate (9) B140 brake
Feeler gauge Brake disk (3) Feeler gauge Brake disk (3)
Magnet assembly (9) Magnet assembly (9)
End cap (6) End cap (6)

214228k3.p65/121201
Stop plate (1)

Armature disk (2)
Armature disk (2)
41777444.eps 41777445.eps
19
Fit the fan and secure it with the retaining ring. Fit the fan cover
Tightening torque
ZB. 63 – 100 motor = 4 Nm
Ensure the retaining ring clicks correctly into place. ZB. 112 – 132 motor = 6 Nm
ZB. 160 – 225 motor =10,5 Nm
41432144.eps 41431945.eps
6.3.2 Replacing the brake disk 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.
Undo the four screws and remove the fan cover. Remove the retaining ring and fan.
41431944.eps 41432144.eps 41432244.eps

214228k3.p65/121201
20
B003 brake B004-B680 brakes
Remove terminal box cover (11). Remove terminal box cover (11).
Loosen hexagon nut (10), pull off washers (15), magnet Loosen hexagon nut (10) and pull off magnet assembly (9).
assembly (9) and covering tape (12).
42508644.eps 42022544.eps
Remove stop plate (1), friction plate (2), distance springs (5) Remove stop plate (1), armature disk (2), distance springs (5) and
and brake disk (3). brake disk (3).
Check grub screws (4), sleeve (13) and braking surfaces for Check collared pins (4) and braking surfaces for wear.
wear.
Replace worn or damaged parts.
42508344.eps 42288144.eps
214228k3.p65/121201
21
Disassembly/assembly of the B003 brake Disassembly/assembly of the B004-B680 brakes
Grub screws/end shield (6) – if required collared pins/end shield (6) – if required
Remove end shield (6). Remove end shield (6).
Remove sleeve (13) and friction disk (14). Unscrew the three defective collared pins (4).
Unscrew the three defective grub screws (4). Fit new collared pins (4).
Fit new grub screws (4). Refit new end shield (6).
Friction disk (14) is provided with mark “I”.
End shield (6) is also provided with a mark.
B004-B050 brakes for ZBF motor
When fitting friction disk (14) ensure that the mark of friction
disk (14) is aligned with the mark of end shield (6). Retaining plate (7) is only fitted for
Slide sleeve (13) onto grub screws (4). type of enclosure IP55.
Refit new end shield (6). Fit retaining plate (7) with collared
pins (4).
Mark “I” on friction disk (14)
Mark on end shield (6)
42508444.eps 42287944.eps
Tightening torque of collared pins/grub screws

Brake size B003/004 B007 B020 B050 B140 B280 B680
Tightening torque 3 Nm 3 Nm 4 Nm 9 Nm 30 Nm 70 Nm 140 Nm
214228k3.p65/121201
22
Fitting the brake Fitting the brake
Recess on friction disk (2) Bore hole on stop plate (1)
Mark “I” on friction disk (14)

Mark “I” on armature disk (2)
Bore hole on
stop plate (1)
Fit brake disk (3).

The recess on the outer diameter and the bore hole on stop plate (1) Fit brake disk (3).
must be aligned with the mark on end shield (6) when fitting friction Mark “I” and the bore hole on stop plate (1) must be aligned with the
disk (2). mark on end shield (6) when fitting armature disk (2).
The machined surface of friction disk (2) is the opposite surface of the
brake disk.
42508344.eps 42288144.eps
B003 brake Push distance spring (5) onto grub screws (4).
ZBA/ZBF motor Place brake springs (8) into magnet assembly (9).
Insert covering tape (12) into the groove of end shield (6).
Push magnet assembly (9) and disks (15) over grub screws (4) and secure with
hexagon nut (10).
Brake spring (8) When fitting magnet assembly (9) ensure that covering tape (12) engages the
groove of magnet assembly (9).
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 = 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-assem-
bled.
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).
Arrangement of brake springs (8)

Spring
42508244.eps Brake torque Number of brake springs Part no.
arrangement
Nm white red blue yellow see item
2,5 3 - - - 1) 260 010 84
1,9 - 3 - - 2) 260 011 84
1,4 - - 3 - 3) 260 027 84
0,9 - - - 3 4) 260 013 84
1) 2) 3) 4)
214228k3.p65/121201
33 wt
ws 33 rd
rt 3 bl 33 ge
yl 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 circumfer-
ence. If the measured result is within the specified range, the motor can be
re-assembled.
• Pull the connecting cable of magnet assembly (9) back into the terminal box.
• Fit terminal box cover (11).
42022444.eps
Adjusting angle a 1 120° 120° 120° 90° 80° 70° 60°
Brake spring Part no.
Spring white – 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 – –
Arrangement of brake springs for motor without manual brake release unit
Brake size B 004 B 007 B 020 B 050 B 140 B 280 B680
Number of springs For spring arrangement see

Brake torque M B in Nm
white red blue item
6 0 0 5 – 7,6 20 50 140 280 680

4 2 0 6 – 5,9 16 39 105 220 530
3 3 0 7 – 5,1 13 33 94 185 450
3 0 0 8 – 3,8 10 25 70 140 340
2 2 0 9 – 3,4 9 22 62 125 300
0 6 0 10 – 2,5 6,6 17 47 93 230
0 4 0 11 1,7 1,7 4,4 11 31 62 150
0 3 0 12 1,3 1,3 3,3 8,3 23 46 115
0 4 2 13 2,3 – – – – – –
0 0 6 14 1,8 – – – – – –
0 0 4 15 1,2 – – – – – –
0 0 3 16 0,9 – – – – – –
214228k3.p65/121201
24
Arrangement of brake springs for ZBA motors
5) 6) 7) 8) 9)
6 wt
ws wt, 2rd
4 ws, 2rt 3
3 wt,
ws, 3rd
3 rt 3 3ws
wt 6 ws,
2 wt, 2rd
2 rt
10) 11) 12) 13) 14)
66 rd
rt 4 rd
rt rd
3 rt 44 rt,
rd,22blbl 6 bl
15) 16) 17) 18) 19)
4 bl 3 bl 44
rd,rt,11bl
bl rd,1bl
3 rt, 1 bl rd,1bl
5 rt, 1 bl
20) 21) 22)
11rt,
rd,55blbl 5 bl 4 bl
= Bore hole, = wt, = rd, = bl, = ye,

empty white spring red spring blue spring yellow spring
42506846.eps
Arrangement of brake springs for motor with manual brake release unit
Brake torque MB in Nm
white red blue item
6 0 0 5 – 7,6 20 50 140 280 680

4 2 0 6 – 5,9 16 39 105 220 530
3 3 0 7 – 5,1 13 33 94 185 450
3 0 0 8 – 3,8 10 25 70 140 340
2 2 0 9 – 3,4 9 22 62 125 300
0 6 0 10 – 2,5 6,6 17 47 93 230
0 4 1 17 – 1,7 4,4 11 31 62 150
0 3 1 18 – 1,3 3,3 8,3 23 46 115
0 4 1 17 1,7
0 3 1 18 1,3
0 5 1 19 2,3
214228k3.p65/121201
0 1 5 20 1,8
0 0 5 21 1,2
0 0 4 22 0,9
25
B004, B020, B050, B140 brakes
ZBF 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 circumfer-
ence. If the measured result is within the specified range, the motor can be
re-assembled.
• 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°
Brake spring Part no.
Spring white - 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
Arrangement of brake springs for motor without manual brake release unit
Brake size B 004 B 020 B 050 B 140

Brake torque M B in Nm
red blue item
4 2 26 2,3 5,6 13 37
4 0 27 1,7 4,4 11 31
3 0 28 1,3 3,3 8,3 23
0 6 29 1,8 (3,3) 6,3 18
0 4 30 1,2 2,2 4,2 12
0 3 31 0,9 1,7 3,2 8,8
Arrangement of brake springs for motor with manual brake release unit
Brake size B 004 B 020 B 050 B 140
For spring arrangement see
Number of springs Brake torque M B in Nm
item
red blue
5 1 32 2,3 5,6 13 –
5 0 33 – – – 37
4 1 34 1,7 4,4 11 31
3 1 35 1,3 3,3 8,3 23

214228k3.p65/121201
1 5 36 1,8 (3,3) 6,3 –
1 4 37 – – – 18
0 5 38 1,2 2,2 4,2 12
0 4 30 0,9 1,7 3,2 8,8

26
Arrangement of brake springs for ZBF motors
26) 27) 28) 29) 30)
4 rd,
rt, 22 bl
bl 44 rd
rt 3 rd
rt 6 bl 4 bl
31) 32) 33) 34) 35)
3 bl 55 rd,
rt, 11 bl
bl 5 rt
rd 44 rt,
rd,11blbl 33 rt,
rd,11blbl
36) 37) 38)
11rt,
rd,55blbl 1rt,
1 rd,4 4blbl 5 bl
= Bore hole, = wt, = rd, = bl, = ye,

empty white spring red spring blue spring yellow spring
42506946.eps
Fit the fan and secure it with the retaining ring. Fit the fan cover
Tightening torque
ZB. 63 – 100 motor = 4 Nm
Ensure the retaining ring clicks correctly into place.
ZB. 112 – 132 motor = 6 Nm
ZB. 160 – 225 motor = 10,5 Nm
41432144.eps 41431945.eps
214228k3.p65/121201
27
6.3.3 Tightening torques of bolts 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 M5 M6 M8 M 10 M 12 M 16
Tightening torque 6,2 Nm 10,5 Nm 25 Nm 50 Nm 86 Nm 215 Nm
For VERBUS RIPP self-locking bolts for • IM B 3 foot mounting

• IM B 5 flange mounting
Bolt size M5 M6 M8 M 10 M 12 M 16
Tightening torque
7,5 Nm 14 Nm 30 Nm 65 Nm 100 Nm 270 Nm
for cast iron
Tightening torque
9 Nm 18 Nm 45 Nm 75 Nm – –
for cast aluminium
6.4 Options The following options are available:

• Sealing (covering tape) for IP55, brake types B 004 – B 680
It is an option for brake types B 004 – B 680, however standard for B003 brakes.
• Reduced noise level
– Option for brake types B004 – B050
– Standard for brake types B 140 – B 680
• Manual brake release unit
At present, the manual brake release unit is only available for brakes B 004 –
B 680.
• Micro-switches
A micro-switch arrangement is only possible for brake types B 004 – B 680, not for
B003 brakes.
214228k3.p65/121201
28
6.4.1 Sealing of B 004 – B 680
brakes, IP55
Removing the covering tape
41766444.eps 41766544.eps 41766644.eps
Loosen the terminal box cover. • Pull off the terminal box cover. Pull off the covering tape, if necessary, use a
• Disconnect the supply cable of the brake. suitable tool, e.g. a screw driver.
• Pull the supply cable of the brake out of the
terminal box.
Fitting the covering tape
41766644.eps 41766544.eps 41766444.eps
Fit the covering tape, if necessary, use a • Insert the supply cable of the brake into the Close the terminal box cover by tightening the
suitable tool, e.g. a screw driver. terminal box. 4 screws. Tightening torques in accordance
• Connect the supply cable of the brake. with table “Tightening torques of screws, sec-
• Fit the terminal box cover. tion 6.3.3.
• Make sure the sealings are correctly seat-
ed!
6.4.2 Reduced noise level For “Replacing the brake disk”, see section 6.3.2
® Fitting the brake
6.4.3 Manual brake release unit For motors with manual brake release unit, also comply with the “Additional equip-
ment 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 equip-
214228k3.p65/121201
ment for brakes, ZBA – ZBF motor range” operating instructions, ident. no.
214 040 44.
29
7 Motor/brake connection diagrams
7.1 Brake control 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 connect-
ed 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 con-
nected.
Supply and brake voltage

ULine [AC] UBrake [DC]
230 V 104 V
400 V 180 V
Operation with frequency inverters

If ZB. cylindrical rotor brake motors are operated together with inverters, the
brake must be provided with a separate power supply and control.
Brake control modules
• GE brake rectifiers (normal excitation)

GE brake rectifiers are used for single-speed motors as standard, and for pole-
changing motors featuring separate power supply up to brake size
– B050 for ZBA motors
– B140 for ZBF motors.
They mainly consist of a half-wave rectifier with integrated free-wheeling circuit.
Important: When used with a pole-changing motor, GE modules must be
provided with a separate power supply or according to diagram
037 860 84 (see section 7.5).
Note: When SE or VE units are used, no additional cables are necessary.
214228k4.p65/121201
30
• GS brake rectifiers (high-speed excitation)
GS brake rectifiers are used for ZBA motors with brakes from size B140 as stand-
ard. They can be used for single-speed motors as well as for pole-changing mo-
tors with a separate power supply.
GS brake rectifiers can be used as an option for brake sizes B003 to B050. This
makes it possible to achieve shorter brake release times and higher motor starting
frequencies.
Up to brake size B050, two leads are sufficient for control (over-excitation factor
of 2), from brake size B140 on, three leads are required (over-excitation factor
of 2,5).
GS modules include a reversible rectifier which overexcites the brake for ap-
prox. 0,3 seconds to release it and then supplies it with the appropriate holding
voltage from a half-wave rectifier.
As an option, GS rectifiers can also be used for ZBF motors of single-speed de-
sign and also for pole-changing designs if they are provided with a separate power
supply. For ZBF motors, 2 power leads are sufficient up to brake B140.
Important: When used with a pole-changing motor, the GS module must be
provided with a separate power supply or according to diagrams
037 886 84, 038 001 84 and 038 017 84 (see section 7.5).
Note: When SE or VE units are used, no additional cables are necessary.
• GP brake rectifiers (normal excitation for pole-changing motors)

GP brake rectifiers can be used parallel to the motor winding for pole-changing
motors with separate windings up to brake size – B050 for ZBA motors
– B140 for ZBF motors.
For this, it is necessary for both windings to be connected to one phase on the
terminal board (e.g. 1U & 2U). The advantage of using a GP brake rectifier com-
pared to a GE module is that no additional cables are required for the power
supply.
GP rectifiers mainly consist of two half-wave rectifiers which are connected de-
pending on the winding being used.
Note: When SE units are used, no additional cables are necessary.
• GF brake module (combined module)

As standard, the GF combined module is used for pole-changing travel motors
type ZBF, sizes 63 – 100.
It combines three functions in a single module and is used parallel to the motor
winding for normal excitation of the DC brake as the GP module described above.
The function of the SE module is also implemented since motor-current dependent
brake switch-off in the DC circuit is integrated in the GF module.
The GF module also features an integral varistor set that protects the high-pole
winding of the pole-changing travel motors.
GF modules must not be used together with inverters.

For inverter operation, combinations with GE – VE or GS – VE modules must
be used.
214228k4.p65/121201
31
• SE current relays (motor current-dependent high-speed trip relay)
SE current relays can be combined with GE, GS and GP brake rectifiers. They are
used for rapid demagnetization of the brake to achieve fast brake application times
without the need for additional wiring for brake switch-off in the DC circuit.
SE current relays are connected to one motor current phase. When the motor is
switched off, the relay demagnetizes the brake by opening the contact in the
DC circuit.
When SE units are used, no additional cables are necessary to interrupt the power
supply for the brake.
Important: SE modules must not be used together with inverters.
We recommend the use of VE voltage relays for these
applications.
SE current relays can be used for rated motor currents up to 50 A.
• VE voltage relays (voltage-dependent high-speed trip relay)

VE voltage relays can be combined with GE, GS and GP brake rectifiers. In con-
trast to SE current relays, VE voltage relays must only be used for brakes with
a separate power supply.
These modules may preferably be used for inverter-fed motors. They are used for
high-speed demagnetization of the brake to achieve fast brake application times
without the need for additional wiring for brake switch-off in the DC circuit.
VE voltage relays are connected to the brake power supply. The contact in the
DC circuit is opened when the brake is switched off.
Brake control module technical data

Module Part no. Voltage range Max. continuous brake Remarks
direct current
in V 1) A
260 892 84 110 ... 500 1,5
GE
260 890 84 42 ... 500 3
260 893 84 110 ... 500 1,5
GP
260 891 84 42 ... 500 3
GS 260 894 84 110 ... 500 1 2) Over-excitation factor: 2 or 2,5
VE 260 897 84 42 ... 500 2
3) Control current range
(single phase motor current)
260 864 84 0,25 ... 4 A
SE 260 870 84 42 ... 500 2 0,8 ... 16 A
260 896 84 1,2 ... 50 A

GF 260 943 84 220 ... 500 0,8 0,25 ... 16 A for ZBF 63 - 100
1) Sinusoidal voltages
2) •2 leads ® Over-excitation factor of 2
•3 leads ® 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
32
Field of application of the brake control modules:
• GE, GP, GS brake rectifiers
• GF combined module
Brake voltage Brake size
U AC U DC B 003 B 007 B 020 B 050 B 140 B 280 B 680
V V
GE [3,0 A]
42 – 109 19 – 49
GP [3,0 A]
GE [1,5 A]
110 – 500 50 – 225 GP [1,5 A] GS [1,0 A]
GS [1,0 A]
190 – 500 86 – 225 GS [1,0 A]

260 – 500 117 – 225 GS [1,0 A]
220 – 500 99 – 225 GF [0,8 A] 1)
1) Used for ZBF motors only!
U AC = Brake control module input voltage

U DC = Brake control module output voltage ® brake supply voltage
• SE current relays, VE voltage relays
Brake size
B 003 B 00 7 B 020 B 050 B 140 B 280 B 680
Brake voltage Brake voltage Brake voltage

U AC U DC U AC U DC U AC U DC
V V V V V V
42 - 500 19 - 225 53 - 500 24 - 225 110 - 500 50 - 225
SE 2A
VE 2A
U AC = Brake control module input voltage

U DC = Brake control module output voltage ® brake supply voltage
214228k4.p65/121201
33
Brake selection table
Standard Brake Supply Allocated standard modules Remark

braking torque voltage
ZBA ZBF ZBA ZBF
single -speed or Part no. single- Part no. pole- Part no.
pole-changing speed changing
[ V AC]
42 - 109 GE [3,0 A] 260 890 84 GE [3,0 A] 260 890 84 a) Supply from a separate
DC voltage source is
+ SE 1) possible without any
£ 2,5 Nm £ 2,5 Nm B 003 limitations.
110 - 500 GE [1,5 A] 260 892 84 GE [1,5 A] 260 892 84
Voltage range:
+ SE 1)
19 - 225 V DC
42 - 109 GE [3,0 A] 260 890 84 GE [3,0 A] 260 890 84
+ SE 1)
£ 7,6 Nm – B 007
110 - 500 GE [1,5 A] 260 892 84 GE [1,5 A] 260 892 84 b) The GF module has a
limited
+ SE 1)
voltage range:
GF [0,8 A] 260 943 84
42 - 109 GE [3,0 A] 260 890 84 GE [3,0 A] 260 890 84 220 - 500 V AC
+ SE 1)
£ 20 Nm £ 5,5 Nm B 020
110 - 500 GE [1,5 A] 260 892 84 GE [1,5 A] 260 892 84
+ SE 1)
42 - 109 GE [3,0 A] 260 890 84 GE [3,0 A] 260 890 84
+ SE 1)
£ 50 Nm £ 13,2 Nm B 050
110 - 500 GE [1,5 A] 260 892 84 GE [1,5 A] 260 892 84
+ SE 1)
42 - 109 – – GE [3,0 A] 260 890 84 GP [3,0 A] 260 891 84
+ SE 1) + SE 1) Supply from a separate DC

£ 140 Nm £ 37,3 Nm B 140 voltage source is not possible
110 - 500 GS [1,0 A] 260 894 84 GE [1,5 A] 260 892 84 GP [1,5 A] 260 893 84
Exception:
+ SE 1) + SE 1) B 140 brake with braking
42 - 189 – – – – – – torque £ 37,3 Nm
£ 280 Nm – B 280
190 - 500 GS [1,0 A] 260 894 84 – – – –
Voltage range:
42 - 259 – – – – – – 19 - 225 V DC
£ 680 Nm – B 680
260 - 500 GS [1,0 A] 260 894 84 – – – –
1) The SE modules are allocated as follows depending on the rated motor current:
Rated motor current Module Part no.
£ 4A 260 864 84
£ 16 A SE 260 870 84
£ 50 A 260 896 84
214228k4.p65/121201
34
7.2 Brake operating times Brake application times are highly dependent on the way in which the brake is con-
nected.
• 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 overhaul-
ing 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:
• t11 Brake release time with normal excitation (GE, GP, GF) 1)
• t12 Brake release time with high-speed excitation (GS) 1)
• t21 Brake application time for switch-off in the AC circuit
• t22 Brake application time for switch-off in the DC circuit (contact)
• t23 Brake application time for switch-off in the DC circuit (SE, GF, VE)
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.
7.2.1 ZBA range brake operating Size Release time in ms Application time in ms
times
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.
214228k4.p65/121201
35
7.2.2 ZBF range brake operating Size Release times in ms Application times in ms
times
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.
7.2.3 Brake power consumption
Supply voltage 400 V AC (180 V DC), control with brake modules

Temperature range: - 20° C to +60° C
Brake size Excitation with Excitation with GS module Excitation with GS module
GE, GF or GP module Over-excitation factor of 2 Over-excitation factor of 2,5
Release current Holding current Release current Holding current
A A A A 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
B 280 1,13 0,45
B 680
Operation not permissible! 1,80 0,71
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.
Separate brake control with 24 V DC

Temperature range: - 20° C to + 60° C
S i ze Current consumption
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
Note: 1) Operation of the B 140 brake is only permissible up to a brake torque of 37,3 Nm.
214228k4.p65/121201
36
7.3 Selection criteria 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: • The motor and brake of inverter-fed drives must have separate
power supplies
• SE modules must not be used with inverter-fed drives.
• Connection diagrams
– Connection diagram selection (flow chart) for line and inverter-fed
drives and related tables ® section 7.5.
– Connection diagrams ® section 7.5.
Diagrams shown in numerical order according to ident. number.
– Place connection diagram in the terminal box cover on the motor.
• Condition when supplied for inverter operation:
If the motor has been ordered for inverter operation, the brake con-
trol modules GE or GS are NOT connected to the motor winding.
For operation the brake control module must be supplied separately
with AC voltage.
• Designation of the terminal board
The terminal designations used in the connection diagrams are print-
ed on the white motor connecting leads. The designations on the
terminal board in the motor apply to single-speed motors with 6 con-
necting leads.
214228k4.p65/121201
37
7.4 Z motors standard
connection diagrams
to EN standards
7.4.1 ZBF travel motors
Motors with one speed (D / Y)
ZBF motors Brakes Control Line voltage

module
Sizes £ 500V Example Connection > 500V Example Connection

diagram diagram
Line: Line: 525V
63 – 132 B 003 – B 140 GE + SE UBr = UM UM: 400V 037 882 84 UBr = UM / Ö 3 UM: 525V 037 858 84
UBr: U Br : 300V
UM Motor voltage
U Br Brake voltage
Motors with two speeds, separate windings ( Y / Y)
ZBF motors Brake Control Line voltage

module

diagram diagram
63 – 100 B 003 – B 050 GF Line: 038 337 84 Line: 525V 038 423 84
UBr = UM UM: 400V UBr = UM / Ö 3 UM: 525V
112 – 132 B 140 GP + SE UBr: 037 873 84 UBr: 300V 038 421 84
U M Motor voltage
U B r Brake voltage
7.4.2 ZBA standard motors

with brake
Motors with one speed (D / Y)
ZBA motors Brake Control Line voltage

module
Sizes £ 500 V Example Connection > 500 V Example Connection

diagram diagram
Line: 525 V
63 – 132 B 003 – B 050 GE 037 875 84 U B r = UM / Ö 3 UM: 525 V 037 857 84
Line:
UBr: 300 V
UBr = UM UM: 400 V
GS Line: 525 V
UBr:
132 – 225 B 140 – B 680 three-phase 038 006 84 U B r £ 500 V 1) UM: 525 V 037 859 84 2)
supply UBr: 500 V 1)
UM Motor voltage
U Br Brake voltage
1) with transformer, separately supplied

2) separate supply
214228k4.p65/121201
38
Motors with two speeds, separate windings
Sizes 63 – 132 ( Y / Y )
Sizes 160 – 225 ( Y / D)
ZBA motors Brake Control Line voltage
module

diagram diagram
63 – 132 B 003 – B 050 GE 037 860 84 038 425 84
Line: 400V Line: 525V

132 B 140 U Br = U M U M: 400V 038 001 84 U Br £ 500V 1) U M: 525V 038 427 84
GS
three-phase U Br: 400V U Br: 500V 1)
supply
160 – 225 B 140 – B 680 038 017 84 038 017 84 2)
UM Motor voltage
U Br Brake voltage
1) with transformer, separately supplied

2) separate supply
Motors with two speeds, Dahlander winding
ZBA motors Brake Control module Connection diagram
Sizes
63 – 132 B 003 – B 050 GE 1) 037 880 84
GS 1)
132 – 225 B 140 – B 680 038 015 84
three-phase supply
1) In general separate supply of the brake module,
for voltages > 500 V with transformator
7.4.3 ZNA standard motors without

Speed and type of winding ZNA motors Connection diagram
brake
sizes
One speed 63 – 225 020 323 84
Two speeds, separate winding (Y/Y) 63 – 132 020 332 84
Two speeds, separate winding (Y/D) 160 – 225 028 857 84
Two speeds, Dahlander winding 63 – 225 020 328 84

214228k4.p65/121201
39
7.5 Connection diagram
selection
7.5.1 Line operation
Select connection diagram

for line operation
2 windings (Y/Y) yes

up to size 132 Table 1
Voltage > 500V
no
yes
Special connection Table 2
diagram
yes no
Motor with brake?
no
yes yes
1 line voltage? 1 speed? Table 3
no
no
2 speeds Table 4
2 line voltages,
1 speed Table 5
dual-voltage motor
Common
yes power supply to yes
1 line voltage? Table 6
motor and brake?
no no
B 003 to B 680 Separate yes

AC power supply Table 7
DC brake
no
2 line voltages, Separate

dual-voltage motor DC power supply Table 8
Common
B003 to B 680 power supply to yes
DC brake motor and brake? Table 9
no
Separate yes
AC power supply Table 10
no
214228k4.p65/121201
Separate Table 11
DC power supply
40 41808755.eps
Tables 1 – 2 General overview
1 Motor with 2 windings (Y / Y ) up to size 132, line voltage > 500 V
Power supply Switch-off 1) Brake size Control modules in terminal box
ZBA ZBF GP GF 2 ) GE GS n one
£ B 050 £ B 140 038 420 84 – – – –

ms, ws, gs with contact
B 140 – – – – – –
£ B 050 £ B 140 038 421 84 – – – –

common gs with SE
B 140 – – – – – –
£ B 050 £ B 140 – 038 423 84 – – –

internal
B 140 – – – – – –
£ B 050 £ B 140 – – 038 425 84 038 426 84 –

ws, gs with contact
B 140 – – – – 038 427 84 –
£ B 050 £ B 140 – – 038 429 84 038 431 84 –

separate, AC gs with SE
B 140 – – – – 038 433 84 –
£ B 050 £ B 140 – – 038 430 84 038 432 84 –

gs with VE
B 140 – – – – 038 434 84 –
separate, DC gs with contact £ B 050 £ B 140 – – – – 038 428 84
– – none none – – – – 038 435 84

1) gs DC circuit
ws AC circuit
ms motor circuit
2) Only for ZBF motors, sizes 63 – 100
2 Description of special connection diagrams
Connection Windings Voltages Modules Switch-off in 1) Special

diagram
038 021 84 2 ( Y/ Y ) 1 GE + SE gs only high speed is used
038 186 84 1 ( YY / Y ) 2 GE gs, ws, ms brake coil for high voltage
038 187 84 1 ( YY / Y ) 2 GE + SE gs brake coil for high voltage
038 338 84 2 ( Y/ Y ) 1 GF gs only high speed is used
038 422 84 2 ( Y/ Y ) 1, > 500 V GE + SE gs only high speed is used
038 424 84 2 ( Y/ Y ) 1, > 500 V GF gs only high speed is used, ZBF 63 – 100 motors
1) gs DC circuit
ws AC circuit
ms motor circuit
214228k4.p65/121201
41
Tables 3 – 5 Motors without brake
3 Motor for one line voltage Motor type

one speed
020 323 84
4 Motor for one line voltage Motor type
two speeds two speeds

(separate windings) (Dahlander winding)
Y/Y D/Y
020 332 84 028 857 84 020 328 84
5 Motor for two line voltages Motor type

(e.g. D/Y 230/400 V 50 Hz or one speed
YY/Y 240/480 V 60 Hz) D/Y YY/Y
020 323 84 020 337 84
Tables 6 – 11 Motors with brake
6 Common motor and brake Motor type

power supply
one speed two speeds
(not suitable for inverter operation) (separate windings)
Y/Y D/Y
Switch-off in Switching Brake size for Control module in terminal box
element
ZBA ZBF GE GS GP GF 2) GE GS
DC circuit Contact £ B 050 £ B 140 037 875 84 037 892 84 037 872 84 – 037 860 84 037 886 84 –
³ B 140 – – 038 006 84 – – – 038 001 84 038 017 84
SE 1) 2) £ B 050 £ B 140 037 882 84 037 894 84 037 873 84 – – – –
³ B 140 – – 038 008 84 – – – –
internal – £ B 050 – – – 038 337 84 – – –
AC circuit Contact £ B 050 £ B 140 037 875 84 037 892 84 037 872 84 – 037 860 84 037 886 84 –
³ B 140 – – 038 006 84 – – – 038 001 84 038 017 84
motor circuit – £ B 050 £ B 140 037 875 44 037 892 84 037 872 84 – – – –
³ B 140 – – 038 006 84 – – – – –
1) Fitted in the terminal box
2) Not for inverter operation
7 Separate AC brake supply Motor type

one speed two speeds two speeds
(separate windings) (Dahlander winding)
Y/Y D/Y
element
ZBA ZBF GE GS GE GS GE GS
DC circuit Contact £ B 050 £ B 140 037 875 84 037 892 84 037 860 84 037 886 84 – 037 880 84 037 885 84
³ B 140 – – 038 006 84 – 038 001 84 038 017 84 – 038 015 84
SE 1) 2) £ B 050 £ B 140 037 882 84 037 894 84 037 861 84 037 887 84 – – –
³ B 140 – – 038 008 84 – 038 002 84 038 018 84 – –
VE 1 ) £ B 050 £ B 140 037 876 84 037 893 84 037 862 84 037 888 84 – 037 891 84 037 895 84
³ B 140 – – 038 007 84 – 038 003 84 038 020 84 – 038 016 84
214228k4.p65/121201
AC circuit Contact £ B 050 £ B 140 037 875 84 037 892 84 037 860 84 037 886 84 – 037 880 84 037 885 84
³ B 140 – – 038 006 84 – 038 001 84 038 017 84 – 038 015 84
42
8 Separate DC brake supply Motor type
one speed two speeds two speeds

(separate windings ) (Dahlander winding)
Switch-off in Switching Brake size for No control module in terminal box
element
ZBA ZBF
DC circuit Contact £ B 050 £ B 140 037 897 84 037 898 84 037 871 84
9 Common motor and brake Motor connection

power supply
(not suitable for inverter operation) D /Y YY/Y

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
³ B 140 – – 037 859 84 – 038 004 84
SE 1) 2) £ B 050 £ B 140 037 858 84 037 884 84 037 864 84 037 890 84
³ B 140 – – 037 865 84 – 038 005 84
AC circuit Contact £ B 050 £ B 140 037 857 84 037 883 84 037 863 84 037 889 84
³ B 140 – – 037 859 84 – 038 004 84
motor circuit – £ B 050 £ B 140 037 857 84 037 883 84 037 863 84 037 889 84
³ B 140 – – 037 859 84 – 038 004 84

10 Separate AC brake supply Motor connection
D/Y YY/Y

element
ZBA ZBF GE GS GE GS
³ B 140 – – 037 859 84 – 038 004 84
SE 1) 2) £ B 050 £ B 140 037 858 84 037 884 84 037 864 84 037 890 84
³ B 140 – – 037 865 84 – 038 005 84
VE 1) £ B 050 £ B 140 037 876 84 037 893 84 037 881 84 037 896 84
³ B 140 – – 038 007 84 – 038 014 84
³ B 140 – – 037 859 84 – 038 004 84

11 Separate DC brake supply Motor connection
D/Y YY/Y

element
ZBA ZBF
DC circuit Contact £ B 050 £ B 140 037 897 84 037 899 84

214228k4.p65/121201
43
7.5.2 Inverter operation
Select connection diagram

for inverter operation
no
Motor with brake? Table 12
yes
Separate AC yes
B004 – B 680
power supply Table 13
DC brake
no
Separate DC
Table 14
power supply
41808844.eps
Tables 12 – 14
12 Motor without brake Motor type
one speed one speed

D /Y Y/YY
020 323 84 020 337 84
13 Separate AC brake supply Motor type
one speed one speed

D /Y Y/YY
Switch off in Switching Brake size for Control module in terminal box
element
ZBA ZBF GE GS GE GS
³ 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
³ B 140 – – 038 007 84 – 038 014 84
³ B 140 – – 038 006 84 – 038 004 84

1) fitted in the terminal box
14 Separate DC brake supply Motor type
one speed one speed

214228k4.p65/121201
D/Y Y/YY
element
ZBA ZBF
44 DC circuit Contact £ B 050 £ B 140 037 897 84 037 899 84

7.6 Connection diagrams
Motor for one line voltage or
dual voltage motor ( 1: 3 )
Y high voltage
D low voltage
For inverter operation, connect motor with

Y or D connection according to inverter settings
Motor supplied with:

Jumper parts to connect the motor winding with Y
or D connection enclosed.
020 323 84 02032384.eps
Motor for one line voltage

Pole-changing, Dahlander winding D for low speed
YY for high speed
Switch-over to high speed winding via external

supply switch-over and jumper.
02032884.eps Motor supplied with:

Motor connection ends connected to terminal
020 328 84 board as shown.

Pole-changing, separate windings 1U, 1V, 1W for low speed
2U, 2V, 2W for high speed
* = Supply to high speed winding via external

switch-over
214228k5.p65/121201

Jumper parts to connect the motor winding
020 332 84 02033284.eps enclosed.
45
Dual voltage motor (1:2)
YY low voltage
Y high voltage
For inverter operation, connect motor with YY or Y

connection according to inverter settings.

• Motor winding connected with Y connection.
• Jumper parts to connect the motor winding
with YY connection enclosed.
020 337 84 02033784.eps

Pole-changing, separate windings 1U, 1V, 1W for low speed

switch-over

Jumper parts to connect the motor winding
enclosed.
028 857 84 02885784.eps
Dual voltage motor ( 1: 3 ) A: Common power supply to motor and brake

Y high voltage D low voltage
Brake coil rated for the low voltage. Not suitable for inverter operation.
B: Separate power supply to brake

For inverter operation, connect the motor with
Y or D connection according to inverter settings.
Switch-off in the DC circuit

• Remove jumper between terminals 3 and 4.
• Connect a contactor between terminals 3 and 4.
Switch-off in the AC circuit

03785784.eps • Jumper between terminals 3 and 4.
Motor supplied with: • Contactor in the power line to terminal 5.
• Jumper parts to connect the motor winding with Y or D connection enclosed.

• Brake connected to terminals 1 and 2 of the GE module. Motor current switch-off
• Jumper between terminals 3 and 4 of the GE module. Jumper between terminals 3 and 4
214228k5.p65/121201
• Line operation: GE module connected with the motor winding according to variant A. ® not possible for separate power
• Inverter operation or supply to the brake
separate power
supply to the brake: – GE module not connected to the motor winding.
– Power supply by the customer according to variant B.
46 037 857 84
Dual voltage motor ( 1: 3 ) Y high voltage
A: Common power supply to motor and brake D low voltage
B: Separate power supply to brake Brake coil rated for the
low voltage.
Switch-off in the DC circuit dependent on motor

current
Not suitable for inverter operation.
03785884.eps
• 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 according to variant Y.
• Line operation: GE module connected with the motor winding according to variant A.
• Separate power
037 858 84
A: Common power supply to motor and brake

Dual voltage motor ( 1: 3 )
Brake coil rated for the low voltage. Not suitable for inverter operation.

For inverter operation, connect the motor with Y or
D connection according to inverter settings.


• Jumper between terminals 3 and 4.
• Contactors in the power lines to
terminals 5 and 6.
03785984.eps
Motor current switch-off
Jumper between terminals 3 and 4
• Jumper parts to connect the motor winding with Y or D connection enclosed. ® not possible for separate power
• Brake connected to terminals 1 and 2 of the GS module. supply to the brake
• Jumper between terminals 3 and 4 of the GS module.
214228k5.p65/121201
• Line operation: GS module connected with the motor winding according to variant A.
• Inverter operation or
separate power
supply to the brake: – GS module not connected to the motor winding.
037 859 84
47
Motor for one line voltage, pole-changing, separate windings A: Common power supply to motor and brake
* = Supply to high speed winding via external switch-over
1U, 1V, 1W for low speed
2U, 2V, 2W for high speed Not suitable for inverter operation.


• Contactor in the power line to terminal 5
03786084.eps
• Jumper parts to connect the motor winding enclosed.
• Jumper between terminals 3 and 4 of the GE module.
• Line operation: GE module connected with the motor winding according to variant A
(1U connected to terminal 6; terminal 5 free).
Important: The brake will not function without an external power supply
to terminal 5 of the GE module.
• Separate power
037 860 84
Motor for one line voltage, pole-changing, separate windings

Separate power supply to brake * = Supply to high speed winding via external
switch-over.


current
A = Intermediate terminal
03786144.eps

• Motor winding connected as in connection diagram (1U and 2U connected to
one terminal)
214228k5.p65/121201

• 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.
48 037 861 84
Separate power supply to brake
switch-over.

Voltage-dependent switch-off in the DC circuit
03786244.eps

• VE module connected to terminals 1, 3 and 4 of the GE module.
037 862 84
Dual voltage motor 1:2 A: Common power supply to motor and brake
Brake coil rated for the low voltage
YY low voltage Y high voltage

YY or Y connection according to inverter set-
tings

• Remove jumper between terminals 3 and 4
• Connect a contactor between terminals 3 and 4

Motor supplied with: 03786344.eps • Jumper between terminals 3 and 4
• Jumper parts to connect the motor winding with YY connection enclosed.
• Brake connected to terminals 1 and 2 of the GE module. Motor current switch-off
• Jumper between terminals 3 and 4 of the GE module. • Jumper between terminals 3 and 4
• Line operation: GE module connected with the motor winding according to ® not possible for separate power
214228k5.p65/121201
variant A. supply to the brake

separate power
037 863 84 49
Dual voltage motor 1:2 YY low voltage
Y high voltage


current
03786484.eps

• SE module connected with intermediate terminal A and with the motor winding via U1.
• Separate power
037 864 84

low voltage.

current
03786584.eps

• Brake connected to terminals 1 and 2 of the GS module.
• SE module connected to terminals 3 and 4 of the GS module.
214228k5.p65/121201

• Separate power
50 037 865 84
Motor for one line voltage,
YY for high speed
Switch-over to high speed winding via external

supply switch-over and jumper.
Separate DC supply to brake
03787184.eps

Brake connected to Euro terminals.
Important: The brake will not function without a sepa-
rate DC supply to the brake.
037 871 84

Common power supply to motor and brake * = Supply to high speed winding via external
switch-over.


• Connect contactor between terminals 3 and 4

03787284.eps • Jumper between terminals 3 and 4

Motor supplied with: Jumper between terminals 3 and 4
• Brake connected to terminals 1 and 2 of the GP module.
214228k5.p65/121201
• Jumper between terminals 3 and 4 of the GP module.

• GP module connected with the motor winding as in the connection
diagram.
037 872 84 51
Common power supply to motor and brake * = Supply to high speed winding via external
switch-over.


current
03787384.eps

• Motor winding connected as in connection diagram (1U and 2U connected to one terminal).
• 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
Motor for one line voltage A: Common power supply to motor and brake


• Jumper between terminals 3 and 4
03787584.eps Motor current switch-off

® not possible for separate power
Motor supplied with: supply to the brake

214228k5.p65/121201
separate power
supplyto the brake: – GE module not connected to the motor winding.
52 037 875 84
Motor for one line voltage or dual voltage motor ( 1: 3 ) Y high voltage
D low voltage

For inverter operation, connect motor with Y or D
03787644.eps

037 876 84

YY for high speed
Switch-over to high speed winding via external supply

switch-over and jumper.
Separate power supply to brake.


03788084.eps
214228k5.p65/121201
037 880 84 53
Dual voltage motor 1:2 YY low voltage
Y high voltage

03788184.eps
• Motor winding connected with Y connection
037 881 84

A: Common power supply to motor and brake current
03788284.eps
214228k5.p65/121201

• Separate power
54 037 882 84
Dual voltage motor ( 1: 3 ) A: Common power supply to motor and brake
Brake coil rated for the low voltage.


03788384.eps Motor current switch-off

Motor supplied with: Jumper between terminals 3 and 4
• Jumper parts to connect the motor winding with Y or D connection enclosed. supply to the brake
separate power
037 883 84

low voltage.

current
03788484.eps
214228k5.p65/121201

• Separate power
037 884 84 55
YY for high speed



03788584.eps
terminals 5 and 6 of the GS module.
037 885 84

2U, 2V, 2W for high speed Not suitable for inverter operation.


• Contactor in the power line to terminal 5.
03788684.eps
• Line operation: GS module connected with the motor winding according to variant A
(1U connected to terminal 6; terminal 5 free).
214228k5.p65/121201
Important: The brake will not function without an external power supply to
terminal 5 of the GS module.
• Separate power
56 037 886 84
Separate power supply to brake * = Supply to high speed winding via
external switch-over.


current
03788784.eps
• Motor winding connected as in connection diagram (1U and 2U connected to one
terminal).
terminal 1U 2U.
Important: The brake will not function without a separate power supply to termi-
nals 5 and 6 of the GS module.
037 887 84


03788884.eps

• VE module connected to terminals 1, 3 and 4 of the GS module.
214228k5.p65/121201
037 888 84
57
Dual voltage motor (1:2) A: Common power supply to motor and brake

For inverter operation, connect the motor with YY
or Y connection according to inverter settings

• Connect a contactor between terminals 3
and 4.
• Jumper between terminal 3 and 4.
Motor supplied with: 03788984.eps
• Connect a cantactor contact in the cable to
• Motor winding connected with Y connection. terminal 5.
• Brake connected to terminals 1 and 2 of the GS module. Motor current switch-off
• Jumper between terminals 3 and 4 of the GS module. Jumper between terminals 3 and 4
• Line operation: GS module connected with the motor winding according to variant A. ® not possible for separate power
separate power
037 889 84
Dual voltage motor (1:2) YY low voltage

Y high voltage


current

03789084.eps A = Intermediate terminal
• SE module connected with intermediate terminal A and the motor winding via U1.
214228k5.p65/121201
• Separate power
58 037 890 84
YY for high speed

Voltage-dependent switch-off in the DC circuit.
03789184.eps
037 891 84



03789284.eps
Motor supplied with: supply to the brake
214228k5.p65/121201
separate power
037 892 84 59
Motor for one line voltage or Y high voltage
dual voltage motor ( 1: 3 ) D low voltage

03789384.eps
037 893 84
Motor for one line voltage Switch-off in the DC circuit dependent on motor
current
03789484.eps
214228k5.p65/121201

• Separate power
60 037 894 84
YY for high speed

03789584.eps
terminals 5 and 6 of the GS module
037 895 84

Y high voltage

or Y connection according to inverter settings.

214228k5.p65/121201
037 896 84 03789684.eps

61

03789784.eps

• Brake connected to Euro terminals.
Important: The brake will not function without a separate
DC supply to the brake
037 897 84

Separate DC supply to brake * = Supply to high speed winding via

03789884.eps

214228k5.p65/121201

62 037 898 84
Y high voltage

03789984.eps

037 899 84



terminals 5 and 6.

• Line operation: GS module connected with the motor winding according to variant A
(1U connected to terminal 7; terminals 5 and 6 free).
214228k5.p65/121201
Important: The brake will not function without an external power supply
to terminals 5 and 6 of the GS module.
• Separate power
038 001 84
63


current
03800284.eps

• 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

* = Supply to high speed winding via

03800384.eps

214228k5.p65/121201
terminals 5, 6 and 7 of the GS module.
64 038 003 84
Dual voltage motor (1:2) A: Common power supply to motor and brake

or Y connection according to inverter settings

Motor supplied with: • Contactors in the power lines to
03800484.eps
• Motor winding connected with Y connection. terminals 5 and 6.
• Line operation: GS module connected with the motor winding according to variant A. supply to the brake
separate power
038 004 84

Y high voltage


current

214228k5.p65/121201
• SE module connected with intermediate terminal A and the motor winding via U1.
• Separate power
038 005 84 65



03800684.eps terminals 5 and 6.
Motor supplied with: Motor current switch-off
• Brake connected to terminals 1 and 2 of the GS module. supply to the brake
separate power
038 006 84


03800784.eps
214228k5.p65/121201
66 038 007 84
Motor for one line voltage Switch-off in the DC circuit dependent on motor
current

• Separate power
038 008 84

Y high voltage

YY or Y connection according to inverter settings.
03801484.eps

214228k5.p65/121201

038 014 84 67
YY for high speed



03801584.eps terminals 5 and 6

038 015 84

YY for high speed

03801684.eps
214228k5.p65/121201
68 038 016 84


• Contactor in the power line to terminals
5 and 6.

• Line operation: GS module connected with the motor winding according to
variant A (1U connected to terminal 6; terminals 5 and 6 free).
Important: The brake will not function without an external power
supply to terminals 5 and 6 of the GS module.
• Separate power
038 017 84



current
03801884.eps

• Motor winding connected as in connection diagram (1U and 2U connected to one
terminal).
214228k5.p65/121201

terminal 1U 2U.
038 018 84 69
* = Supply to high speed winding via

03802084.eps

038 020 84

Common power supply to motor and brake

Only high-speed winding is used.
03802184.eps

214228k5.p65/121201
• 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
Motor for one line voltage YY low voltage
or dual voltage motor (1 : 2) Y high voltage
A: Common power supply to motor and brake.

Brake coil only rated for the high voltage.
B: Separate power supply to brake.

or Y connection according to inverter settings.

03818684.eps • Remove jumper between terminals 3 and 4
Motor supplied with: • Connect a contactor between terminals 3 and 4
• Line operation: GE module connected with the motor winding according to variant A. Motor current switch-off
• Inverter operation or • Jumper between terminals 3 and 4
separate power ® not possible for separate power
supply to the brake: – GE module not connected to the motor winding. supply to the brake
038 186 84
Motor for one line voltage YY low voltage

or dual voltage motor (1 : 2) Y high voltage

Brake coil only rated for the high voltage
03818784.eps
• SE module connected with intermediate terminal A and with the motor winding via U1.
214228k5.p65/121201
• Separate power
038 187 84 71
switch-over.

03833784.eps

• 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.
038 337 84
Motor for one line voltage, pole-changing, separate windings 2U, 2V, 2W for high speed
03833784.eps

214228k5.p65/121201
diagram.
72 038 338 84
switch-over.
N0 N10

1U 1V 1W 2U 2V 2W
401 402
1L1*
1L1 1L2* 1L3*
2U
1U 2V 2W N10 GP
~ ~ ~ - +
1V 1W N0
7 6 5 4 3 2 1
1L2 1L3 2U 402 401

N10 N0 1U Switch-off in the DC circuit
S
• Connect a contactor between terminals 3
03842084.eps
and 4.
• Contactors in the power lines to terminal 5.
Motor supplied with: Motor current switch-off

Jumper between terminals 3 and 4.
• Jumper between terminal 3 and 4 of the GP module.
• GP module connected with the motor winding as in the connection diagram.
038 420 84
Motor for one line voltage, pole-changing, separate windings * = Supply to high speed winding via external
switch-over.
N0 N10
1U 1V 1W 2U 2V 2W 401 402
1L2* 1L3*
2U
1U 2V 2W N10
SE GP
~ ~ ~ - +
~ ~
A 1V 1W N0
BK BK WH GY 7 6 5 4 3 2 1
2U WH GY
A 1U
1L1 1L2 1L3 N10 N0 A 402 401
1L1* 4 3
GP SE
03842184.eps

214228k5.p65/121201
• 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
switch-over.
N0 N10
1U 1V 1W 2U 2V 2W 401 402
1L2* 1L3*
2U
1U 2V 2W N10
SE GP
~ ~ ~ - +
~ ~
A 1V 1W N0
BK BK WH GY 7 6 5 4 3 2 1
2U WH GY
A 1U
1L1 1L2 1L3 N10 N0 A 402 401
1L1* 4 3
GP SE
03842184.eps

• GP module connected with the motor winding and intermediate terminal A as in the connection
diagram.
038 421 84
N0 N10
1U 1V 1W 2U 2V 2W 401 402
1L2 1L3
2U GE
1U 2V 2W N10
SE
~ ~ ~ ~ - + A = Intermediate terminal
A 1V 1W N0
BK BK WH GY 7 6 5 4 3 2 1
2U
A 1U
WH GY
1L1 A N10 402 401
4 3
GE SE
03842284.eps

214228k5.p65/121201

• 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
switch-over.
N0 N10

1U 1V 1W 2U 2V 2W
401 402
1L2* 1L3*
GF Not suitable for inverter operation.

2U 2V 2W N10
1U - +
A 1V 1W N0 7 6 5 4 3 2 1
N0 N10 A 1U
2U
402 401 A = Intermediate terminal
1L1 1L2 1L3
1L1*
03842384.eps

diagram.
038 423 84
Common power supply to motor and brake Only high-speed winding is used.
N0 N10

1U 1V 1W 2U 2V 2W
401 402
1L2 1L3
2U
GF A = Intermediate terminal
2V 2W N10
1U - +
A 1V 1W N0 7 6 5 4 3 2 1
1U
1L1 N10 A 2U
402 401
03842484.eps

214228k5.p65/121201
diagram.
038 424 84 75
switch-over.
Separate power supply to brake, max. voltage 500V AC
N0 N10

1U 1V 1W 2U 2V 2W 401 402 • Connect a contactor between terminals 3 and 4
1L1* Switch-off in the AC circuit

1L1 1L2* 1L3* • Jumper between terminals 3 and 4
2U
1U 2V 2W N10 GE
~ ~ - +
1V 1W N0
7 6 5 4 3 2 1
1L2 1L3 2L2 2L1 402 401

S
03842584.eps

Important: The brake will not function without a separate power supply to terminals 5 and 6
of the GE module.
038 425 84

Separate power supply to brake, max. voltage 500V AC switch-over.

N0 N10

1U 1V 1W 2U 2V 2W • Remove jumper between terminals 3 and 4
401 402
1L1*
1L1 1L2* 1L3* Switch-off in the AC circuit
2U
1U 2V 2W N10 GS
~ ~ - +
1V 1W N0
7 6 5 4 3 2 1
1L2 1L3 2L2 2L1 402 401

S
03842684.eps

214228k5.p65/121201

Important: The brake will not function without a separate power supply to terminals 5 and 6
of the GS module.
76 038 426 84

N0 N10

1U 2V 1W 2U 2V 2W
401 402 Switch-off in the AC circuit
1L1* • Jumper between terminals 3 and 4
1L1 1L2* 1L3* • Contactor in the power line to terminal 5
2U
1U 2V 2W N10 GS
~ ~ ~ - +
1V 1W N0
7 6 5 4 3 2 1
1L2 1L3 2L3 2L2 2L1 402 401

S
03842784.eps

Important: The brake will not function without a separate power supply to terminals 5 and
6 of the GS module.
038 427 84
Separate DC supply to brake switch-over.

N0 N10
1U 1V 1W 2U 2V 2W 401 402 401 402
1L1*
1L1 1L2* 1L3*
2U
1U 2V 2W N10
401 402
1V 1W N0
L+ L-
1L2 1L3
03842884.eps

214228k5.p65/121201
Important: The brake will not function without a separate DC supply to the brake.
038 428 84 77
switch-over.
N0 N10 2U, 2V, 2W for high speed
1U 1V 1W 2U 2V 2W 401 402
1L2* 1L3* Not suitable for inverter operation.
2U
1U 2V 2W N10
SE GE
~ ~ ~ ~ - +
A 1V 1W N0
BK BK WH GY 7 6 5 4 3 2 1 A = Intermediate terminal
2U
A 1U
WH GY
1L1 1L2 1L3 2L2 2L1 402 401

1L1* 4 3
GE SE
03842984.eps
• 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
N0 N10 1U, 1V, 1W for low speed


1U 1V 1W 2U 2V 2W 401 402
1L1*
1L1 1L2* 1L3*
2U
2V 2W N10 GE
1U
VE ~ ~ - +
1V 1W N0 - + 7 6 5 4 3 2 1
WH BU RD
WH BU RD
1L2 1L3 2L2 2L1 402 401
4 3 1
GE VE
03843084.eps
• VE module connected to terminals 1, 3 und 4 of the GE module.
214228k5.p65/121201
the GE module.
78 038 430 84
N0 N10
1U 1V 1W 2U 2V 2W 401 402
GS
SE
2U
1U 2V 2W N10
~ ~ ~ ~ - +
A 1V 1W N0
BK BK WH GY 7 6 5 4 3 2 1
2U A = Intermediate terminal
A 1U
WH GY
1L1 1L2 1L3 2L2 2L1 402 401

1L1* 4 3
GS SE
03843184.eps
the GS module.
038 431 84


1U 1V 1W 2U 2V 2W 401 402
1L1*
1L1 1L2* 1L3*
2U
2V 2W N10 GS
1U
VE ~ ~ - +
1V 1W N0 - + 7 6 5 4 3 2 1
WH BU RD
WH BU RD
1L2 1L3 2L2 2L1 402 401
4 3 1
GS VE
03843284.eps

214228k5.p65/121201

the GS module.
038 432 84 79

1U 1V 1W 2U 2V 2W 401 402
2U GS
1U 2V 2W N10
SE
~ ~ ~ ~ ~ - +
A 1V 1W N0
BK BK WH GY 7 6 5 4 3 2 1
2U
A 1U
WH GY
1L1 1L2 1L3 2L3 2L2 2L1 402 401

1L1* 4 3
GS SE
03843384.eps
Important: The brake will not function without a separate power supply to terminals 5, 6 and 7 of
the GS module.
038 433 84
switch-over.

1U 1V 1W 2U 2V 2W 401 402
1L1*
1L1 1L2* 1L3*
2U 2V 2W N10 GS
1U
VE ~ ~ ~ - +
1V 1W N0 - + 7 6 5 4 3 2 1
WH BU RD
WH BU RD
1L2 1L3 2L3 2L2 2L1 402 401
4 3 1
GS VE
03843484.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.
80 038 434 84
switch-over.
N0 N10 1U, 1V, 1W for low speed

1U 1V 1W 2U 2V 2W
1L1*
1L1 1L2* 1L3*
2U 2V
1U 2W N10
1V 1W N0
1L2 1L3
03843584.eps

Motor winding connected as in connection diagram (1U and 2U connected to one terminal).
038 435 84
214228k5.p65/121201
81
7.7 Connecting temperature Depending on the motor features, the connections for temperature monitoring and/or
brake monitoring are brought out on Euro terminals in the terminal box.
and brake monitoring
The following connection designations are used:
devices
• PTC thermistor
– Switch-off: 101 - 102 and 201 - 202
– Warning: 111 - 112
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: 801 – 802 – 803
Contact 2 (802 – 803) closed:
Brake not released, brake in applied position
Brake released
– Adjustment monitoring: 804 – 805 – 806
Brake must be adjusted
Normal operating condition
The diagrams below show the most important single connections.

When several monitoring devices are used (such as PTC thermistors for the motor
and release monitoring for the brake), the individual circuits are combined in one
connection diagram which can be found inside the motor terminal box.
PTC thermistor PTC thermistor PTC thermistor PTC thermistorr
3x 3x 3x 6x
Switch-off Switch-off 1 Warning Switch-off
101 102 101 102 111 112 101 102

P1 P2 P1 P2 P11 P12 P1 P2
3x
Switch-off 2
201 202
P21 P22
03781944.eps 03782044.eps 03782144.eps 03782344.eps
PTC thermistor Brake monitoring Brake monitoring Temperature detector

Release monitoring Adjustment monitoring
6x
214228k6.p65/121201
Warning
4 2 1 4 2 1
wh gn bn wh gn bn
111 112 601 602
801 802 803 804 805 806
P11 P12
P1 P2
03782744.eps 03781644.eps 03781744.eps 03782244.eps
82
8 Technical data
Function conditions for standard design
Conditions Z range
Transport temperature - 20 ... + 40°C
Storage temperature 0 ... + 40°C
Storage conditions dry, indoors
Ambient operating temperature - 20 ... + 40°C
Environment acid-free
Coolant A ir
Coolant temperature max. + 40°C
Temperature rise limit of winding 105K
Altitude max. 1000 m above sea level
Air circuit Ensure by working clearance, unrestricted air intake
Type of enclosure IP 54
Mounting arrangement 500 V / 50 Hz low vibration
Working clearance at fan end 150 mm at rear
Line voltage 400 V / 50 Hz 480 V / 60 Hz 500 V / 50 Hz
Voltage tolerance ± 10 % of the line voltage
Maximum speed in rpm
Motor size with operational braking Motor size with occasional emergency
(line operation) stop
(inverter operation)
ZBF 63 – 132 3600 – –
ZNA 63 – 100 5000 ZNA 63 – 100 5000
ZNA 112 – 132 4000 ZNA 112 – 132 4000
ZNA 160 – 180A 3600 ZNA 160 – 180A 3600
ZNA 180 B – 225 3000 ZNA 180 B – 225 3000
ZBA 63 – 100 5000

ZBA 63 – 132
3600 ZBA 112 – 132 4000
ZBA 160 – 180 A, with B 140 brake

ZBA 160 – 180A 3600
ZBA 160 – 180 A, with B 280 brake
2000
ZBA 180 B – 225 ZBA 180 B – 225 3000
214228k6.p65/121201
83
9 Troubleshooting
Item Problem Possible cause Solution

1 Motor does not start. Fuse has tripped. Replace fuse.
Power supply line interrupted. Check connections.
Motor protection has tripped. Check motor protection for correct setting.
Control defective. Check motor connection.
Brake does not release. See item 10 "Brake does not release"
2 Motor does not start or starts slowly. Motor for delta connection connected in star. Correct motor connection.
Extreme voltage or frequency deviation from setpoint value. Improve quality of power supply; check power supply
line cross-section.
3 Motor will not start in star Insufficient torque in star connection. If the delta starting current is not too high, start up
connection, only starts in delta direct in star connection, otherwise use larger motor
connection. or special design (contact manufacturer).
Contact fault in star-delta starter. Eliminate fault.
4 Motor runs in wrong direction. Motor incorrectly connected. Interchange two supply leads.
5 Motor hums and has high power Winding defective. Motor must be sent to specialist workshop for repair.
consumption.
6 Fuses trip or motor protection trips Short-circuit in the supply line. Eliminate short-circuit.
immediately. Short-circuit in the motor. Motor must be sent to specialist workshop for repair.
Power supply cable incorrectly connected. Correct connection.
Short-circuit to earth in the motor. Motor must be sent to specialist workshop for repair.
7 Extreme loss of speed under load. Overload. Measure power, use larger motor or reduce load, if
necessary.
Voltage drop. Increase power supply line cross section.
8 Excessive motor temperature rise Overload. Measure power, use larger motor or reduce load, if
(measure temperature). necessary.
Insufficient cooling. Correct cooling air circulation or clear air circulation
channels, fit separate fan, if necessary.
Separate fan not running. Check connection, correct if necessary.
Ambient temperature too high. Reduce power, use larger motor, if necessary.
Delta connection instead of star connection as specified. Correct connection.
Temporary two-phase operation. Intermittent electrical contact in the power supply
line.
Fuse has tripped. Replace fuse.
Mains voltage differs from the rated motor voltage by more Match motor to power supply voltage.
than 10%. Higher voltages are particularly unfavourable for
high-pole motors as their no-load current is close to the
rated current even at normal voltage.
Duty type (S1 - S10, EN 60034-1) exceeded, e.g. starting Adapt operating conditions to corresponding motor
frequency too high. duty type.
9 Excessive noise Friction bearing distorted, dirty or damaged. Realign motor, inspect friction bearings, replace if
necessary.
Rotating parts vibrating. Correct any imbalance.
Foreign bodies in cooling air circuit. Clean cooling air circuit.
10 Brake does not release Incorrect voltage applied to brake control unit. Apply correct voltage (see rating plate).
Brake control unit failure. Change brake control unit, check brake coil
(resistance), check switchgear.
Max. permissible air gap exceeded because the brake lining Adjust the brake (replace the complete brake lining
is worn out. carrier if the lining is worn out).
Voltage drop in the power supply line > 10 %. Ensure correct supply voltage is applied.
Brake coil short-circuit with the winding or housing. Change complete brake with control unit (specialist
workshop), check switchgear.
11 Motor does not brake. Brake lining worn out. Replace the complete brake lining carrier
Manual brake release device incorrectly adjusted. Set adjusting nuts to correct setting.
Manual brake release device locked. Release lock, remove lever.
Incorrect brake torque. Change brake torque.
214228k6.p65/121201
84
10 Forms for documenting the installation, rating plates
Z.. 63 A to Z.. 71 B motors, with/without brake

Installation
Demag Cranes & Components GmbH Made in Germany designation:
EN 60034-1
Typ: 3 ~ IP: Iso : F
Mot.Nr .: %ED kW
kg FI: --- Hz cos ϕ
1/min c/h --- ˚C
V A
V A
Bremse: Nm AC V DC V A
ANR: ASN: EFF.
41806644.eps
Z.. 80 A to Z.. 132 C motors, with/without brake

Installation
designation:
Demag Made in Germany
Cranes & Components GmbH EN 60034-1
Typ: 3~ IP:
Mot.Nr.: Iso.: F %ED
kW cosϕ : Hz
1/min ---- c/h ---- ˚C
V A
V A
Bremse: AC V DC V A
kg FI: ---
ANR: ASN: EFF.
41806744.eps
Z.. 160 A to Z.. 225 B motors, with/without brake

Installation
Demag Cranes & Components GmbH EN 60034-1 designation:
Type: 3 ~ IP Iso.: F
Mot.Nr: %ED kW
Made in Germany
kg Fl: Hz ϕ
cos :
1/min c/h ˚C
V A
V A
Bremse: Nm AC V DC V A
ANR: ASN: EFF.
42002644.eps
214228k6.p65/121201
85
86
Notes
214228k6.p65/121201
1 page(s) Page 1
EC conformity declaration
Ident. no.
Demag AC motor type Z, M
in accordance with EC directive 89/336/EEC, Appendix I, 205 211 44
and 73/23/EEC, Appendix III Issue 0899 EN
Hereby we,
Demag Cranes & Components GmbH

Drives,
declare that the product
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 92/31/EEC and 93/68/EEC
EC Low Voltage Directive 73/23/EEC
amended by 93/68/EEC
Applied harmonised standards:
EN 50081-2 Electromagnetic compatibility

EN 50082-2 Electromagnetic compatibility
EN 60034 Rotating electrical machines

EN 60034-1 Rating and performance
EN 60034-5 Types of enclosures for rotating electrical machines
EN 60034-7 Types of construction and mounting arrangements (IM Code)
EN 60034-8 Terminal markings and direction of rotation
EN 60034-9 Noise limits
EN 60034-14 Mechanical vibration; measurements, evaluation and limits of
vibration severity
EN 60034-18-1 Functional assessment of insulation systems
EN 60529 Types of enclosure (IP Code)
Wetter, 1 August 1999
Place and date of issue
i.V. Ropelius ppa. Peters

Technik und Entwicklung Vertrieb
214228k6.p65/121201
Motoren Antriebstechnik
# = Modifications compared Class. no.

Normung
to previous issue 715 IS 919
87
Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, D-58286 Wetter Not liable for errors or omissions. Subject to change.
Printed in Germany DZS/121201/2T
214228k6.p65/121201
88
Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, D-58286 Wetter Not liable for errors or omissions. Subject to change.

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What are the safety instructions mentioned in the document?

What are the safety instructions mentioned in the document?

What components are included in the product description?

What components are included in the product description?

Operating instructions

Motors, Z motor range

121201 EN 214 228 44 720 IS 919

Document Part no.

Helical gearbox operating instructions

Motor component parts

10 Forms for documenting the installation, rating plate 85

Every individual given the task of transporting, installing, commissioning, operating,

No part of this documentation may be reproduced, utilized or transmitted without

The guarantee is cancelled, for example, in the event of:

0.5 Definitions Owner

• Qualified personnel (electrician)

Warning against electrical hazards

Operating hazard for the installation

Putting motors into operation Do this only

Symbols used on the packing

This way up Fragile Keep dry Protect from heat

Top-heavy No hooks Attach sling here Centre of gravity

2.3 Storage Motors must be stored as follows:

Unless otherwise agreed in the purchase contract, standard conservation is guaran-

3.1.1 Motor type designation

Z B A 100 A 8/2 B 050

1 Demag Cranes & Components GmbH Made in Germany

1 Manufacturer, country of origin, regulations

2 Type designation, no. of phases, enclosure, temperature class, model

3 Motor number, power, duty factor

4 Motor weight, inertia factor, frequency, power factor

5 Speed, switching frequency, ambient temperature > 40 °C

6 Connection, voltage, current

7 Brake: brake torque, supply voltage, coil voltage, coil current

8 Order number, entry number

1 Demag Made in Germany

1 Demag Cranes & Components GmbH EN 60034-1

5 Speed, switching frequency, ambient temperature

B 003 DC brake B004 – B 680 DC brakes

1 Motor end cap 7 Magnet assembly 13 Sealing washer

The motor must be connected as described in section 7 “Motor/brake connection

Connecting pin threads in terminal box

Motor frame size Pins

63, 71, 80, 90 A M4

112, 132, 160, 180 A M6

180 B, 200, 225 M8

The instructions contained in section 5 “Commissioning” must be followed!

5.1 Requirements Before the drive unit is put into service:

Check the motor for: Check Action

6.2 Maintenance schedule

Options: • Sealing (covering tape) for brake types B004 – B680

B 004 – B 680 brakes:

Apart from wear, the brake is virtually maintenance-free.

Brake air gap s 1 min 0,3 0,3 – 0,3 0,3 0,35 – –

Brake size B 003 B 004 B 00 7 B 020 B 050 B 140 B 280 B 680

Motor Brake work until readjustment WN in Ws

ZBA 160 · 10 6 100 · 10 6 100 · 10 6 120 · 10 6 200 · 10 6 1000 · 10 6 1500 · 10 6 2500 · 10 6

ZBF 200 · 10 6 200 · 10 6 – 300 · 10 6 500 · 10 6 900 · 10 6 – –

B003 – B680 brakes