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Operating instructions Brake motors, KBA, KBF, KBS, SBA, SBS ranges 0898 EN 214 318 44 720 IS 911 41239944.eps
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Operating instructionsBrake motors, KBA, KBF, KBS, SBA, SBS ranges
0898 EN 214 318 44 720 IS 911
41239944.eps
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Mannesmann Dematic AG
P.O. Box 67, D-58286 WetterTelephone (+49 2335) 92-0, Telefax (+49 2335) 927676Internet http://www.dematic.com
Manufacturer
Contents
Further documents Description brake motorsKB, SB brake motorsFG microspeed units 203 255 44 714 IS 911
Data • Brake motor dimensionsKBA, KBL squirrel-cage motors, 400 V 201 620 84 714 IS 911
Data • Brake motor dimensionsKBV, KBF travel motors, 400 VSBA slip-ring motors, 400 VKBZ, KBS, SBS torque motors, 400 V 201 619 84 714 IS 911
Squirrel-cage rotor brake motorsKDF/KMF/KBV/KBFfor travel applications 202 549 44 714 IS 911
DataFG microspeed units 200 185 84 714 IS 911
Microspeed unit dimensionsFG range 200 190 84 714 IS 911
Component parts KB 71 – 140 brake motors 200 039 84 721 IS 911
Component parts KB 160 – 225 brake motors 200 333 84 721 IS 911
Component parts SB 100 – 140 brake motors 200 117 84 721 IS 911
Component parts SB 160 – 225 brake motors 200 334 84 721 IS 911
Geared motors, catalogue with price code 203 250 44 714 IS 980
0 Foreword 4
0.1 Copyright 40.2 After-sales service 40.3 Guarantee 50.4 Limitations of liability 50.5 Definitions 6
1 Safety 7
1.1 Symbols 71.2 Intended use 71.3 Prohibited practises, improper use 71.4 Safety instructions 8
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2 Receiving, transport and storage 9
2.1 Receiving 92.2 Transport 92.3 Storage 9
3 Brake motorsKBA, KBF, KBS, SBA, SBS ranges 10
3.1 General information on Demag brake motors 113.2 Inspection 113.2.1 Mechanical 113.2.2 Electrical 113.3 Mounting 123.3.1 Checking the state 123.3.2 Checking the site of installation 123.3.3 Alignment 123.3.4 Type of mounting 123.3.5 Oil-tight type 123.3.6 Outdoor mounting 123.3.7 Conversion of flange mounting into foot mounting 123.4 Transmission elements 133.4.1 Coupling, toothed wheel, belt, pulley 133.4.2 Protection against rust 133.4.3 Balancing 133.4.4 Fitting device 133.5 Connection 143.5.1 Performance of connection work 143.5.2 Switchgear 143.5.3 Protective measures 143.5.4 Trial run 143.6 Maintenance 153.6.1 Bearings 153.6.2 Slip-rings and brushes 153.6.3 Brake 163.7 Brake adjustment 163.8 Exchange of brake ring 173.9 Exchange of brake spring 173.10 Moving terminal box 183.10.1 KB 71 – 140 squirrel-cage motors 183.10.2 SB 100 – 140 slip-ring motors 183.10.3 KB 160 – 225 squirrel-cage motors, SB 160 – 225 slip-ring motors 183.11 Adjusting the air gap 19
4 Mounting instructions 20
4.1 Tightening torques 204.2 Mounting, dismantling of SB slip-ring motors 20
5 Mains connection 21
5.1 One-speed connection 215.2 Dahlander connection for 2 speeds of a 1:2 ratio 215.3 Connection with 2 separate windings for 2 speeds and one voltage 215.4 Connection with one winding for 1 speed and two voltages
of a 1:2 ratio 21
6 Rotor connection 21
6.1 Three-phase rotor 216.2 Two-phase rotor 21
EC conformity declaration 22
EC manufacturer’s declaration 23
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You have purchased a Mannesmann Dematic product. This equipment was manu-factured in accordance with state-of-the-art engineering principles.
These operating instructions are designed to provide the operator with appropriateinstructions for safe and correct operation and to facilitate maintenance.
Every individual given the task of transporting, installing, commissioning, operating,maintaining and repairing our KB., SB. motors and additional equipment must haveread 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 inorder to prevent operating errors and to ensure smooth and trouble-free operation ofour products.
These operating instructions must be treated confidentially. They should only be usedby authorized personnel. They may only be entrusted or made available to thirdparties with the prior written consent of Mannesmann Dematic. All documents areprotected within the sense of copyright law.
No part of this documentation may be reproduced, utilized or transmitted withoutspecific prior consent. Infringements are an offence resulting in obligatory compensa-tory damages. All industrial rights reserved.
For technical information on Mannesmann Dematic products and their systematicapplication, please refer to one of our after-sales service stations, the relevant repre-sentative or to our main office in Wetter.
0 Foreword
0.1 Copyright
0.2 After-sales service
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These operating instructions must be read carefully before installing and putting theproduct into operation.
We assume no liability for damage and malfunctions resulting from failure to complywith the operating instructions.
Wearing parts are not subject to the guarantee, guarantee claims must be made toMannesmann Dematic 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 notpart 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 byMannesmann Dematic.
0.3 Guarantee
All technical information, data and instructions for operation contained in these oper-ating instructions were up-to-date on going to print and are compiled on the basis ofour experience and to the best of our knowledge.We reserve the right to incorporate technical modifications within the scope of furtherdevelopment of this brake motors, KBA, KBF, KBS, SBA, SBS ranges - which are thesubject of these operating instructions.Therefore, no claims can be derived from the information, illustrations and descrip-tions contained in these operating instructions.We assume no liability for damage and malfunctions caused as a result of operatingerrors, noncompliance with these operating instructions or inappropriate repairs.
We expressly point out that only Mannesmann Dematic spare parts and accessoriesapproved by us may be used. Accordingly, this also applies to other manufacturers’parts used.For safety reasons, the fitting and use of spare parts or accessories which have notbeen approved and unauthorized modification and conversion of the hoist unit are notpermitted and exempt Mannesmann Dematic from any liability for damages resultingtherefrom.With the exclusion of any further claims, Mannesmann Dematic is liable for any faultsor omissions on our part within the scope of the warranty obligations entered into inthe original contract. Claims for damages are excluded, irrespective of the legal rea-son from which such claims are derived.Translations are done to the best of our knowledge. We are unable to accept liabilityfor translation errors, irrespective of whether the text is translated by us or on ourbehalf. The original text is definitive alone.The descriptions and illustrations contained in this documentation do not necessarilycorrespond to the scope of delivery or any subsequent spare part delivery. The draw-ings and illustrations are not to scale.Only documentation belonging to the actual order is valid.
0.4 Limitations of liability
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Owner
Owners (employer, company) are defined as persons who own the product and whouse 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 tocarry out special tasks such as installation, operation, setting-up, maintenance includ-ing cleaning, fault elimination and transportation of the product.
Specialist personnel
Specialist personnel are defined as persons assigned by the owner to carry out spe-cific tasks.
• Qualified personnel (electrician)
Qualified personnel (electricians) are defined as persons, who, owing to their tech-nical training, knowledge and experience as well as knowledge of the relevantstandards, are able to assess the tasks given to them and identify potential haz-ards.
• Trained person
Trained persons are defined as persons who have been instructed and trained forthe tasks assigned to them and on the possible hazards resulting from incorrecthandling and who have been informed about the required protective devices, pro-tective measures, relevant regulations, accident prevention regulations and operat-ing conditions and who have proven their qualifications.
• Experienced technician
Experienced technicians are defined as persons, who, owing to their technicaltraining and experience, have sufficient knowledge of the product and are familiarwith the relevant national industrial safety regulations, accident prevention regula-tions, directives and generally accepted engineering standards (e.g. EC Directives,German VDE and VBG regulations) enabling them to judge the safe operatingcondition of KB., SB. motors.
0.5 Definitions
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1 Safety
1.1 Symbols The following symbols and recommendations indicate potential safety hazards orcauses of damage or provide useful information.
Hazard warning
This symbol appears in the operating instructions next to all instructions relating tosafety at work wherever a potential hazard to life and limb exists if the instructions arenot 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 includingthe power supply.
In addition to the safety instructions, observe all general safety regulations and factory-specific accident prevention regulations at all times.
Warning against electrical hazards
Contact with live parts can result in immediate death. Protective covers (e.g. coversand enclosures) marked with this sign may only be opened by qualified electricians.Before opening, all relevant operating, control, feed or other voltages must be discon-nected.
Operating hazard for the installation
This symbol in the operating instructions indicates all warnings which, if not compliedwith, may result in damage to motors.
These motors may be used for all travel, lifting and turning motions in industrial appli-cations. Compliance with the permitted operating conditions must be ensured foroperation of these drives (e.g. enclosure type, ambient temperature, installationheight).
Under certain conditions, operation of standard motors is prohibited as this couldresult in malfunctions, faults in the equipment or hazard to life and limb, e.g.:
• Acidic, corrosive air as coolant.
• Operation outside the permitted temperature range.
• Operation beyond the normal air pressure. Otherwise, power adjustments are nec-essary.
• 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 otherthan that for which they have been designed.
1.2 Intended use
1.3 Prohibited practises,improper use
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1.4 Safety instructions The relevant national accident prevention regulations and the general safety condi-tions must always be observed when our products are operated in order to avoidaccidents 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 result.
Dangerous voltage!
Motors are connected to a mains power supply. Any contact with live parts can leadto very serious injury or even death.
Do this only
• if you have read the operating instructions and the owner has instructed you in alldetails,
• if the operating instructions are available for reference at the place of operation,
• if you are qualified personnel (electrician),
• if you are not under the influence of drugs, alcohol or medication that can adverse-ly affect your ability to react,
• if the general accident prevention, operating and installation regulations(e.g. DIN VDE 0100/0113) have been observed.
Only carry out maintenance and installation work
• 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.
Additional safety instructions
Putting motors into operation
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2 Receiving, transport and storage
2.1 Receiving
2.2 Transport
Symbols used on the packing
2.3 Storage
Protect from heatKeep dryFragileThis way up
Top-heavy No hooks Attach sling here Centre of gravity
Handle motors with utmost care to avoid damage caused by careless loading andunloading, for example.
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 isdelivered.
Contact Mannesmann Dematic in Wetter, Germany, if geared motors are to be storedfor periods of longer than 6 months.
Important! Motors may otherwise be damaged.
41283944 - 41284644.eps
The scope of delivery is specified in the shipping papers. Check the delivery immedi-ately on receipt to ensure that it is complete and examine it for damage caused intransit. If necessary, a damage report must be made out in the presence of the trans-port contractor’s representative as otherwise it will not be possible to rectify the dam-age at no cost to you.
The drive is supplied made up into one unit. Additional equipment may be supplied inseparate packaging.
The drive is packed depending on the transport method and its weight. Unless other-wise agreed in the purchase contract, the packaging corresponds to the packagingguidelines of Mannesmann Dematic, ident no. 236 070 44.
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41415444.eps
1 Shaft2 Motor end cap, drive side3 Spring ring4 Thrust ring5 Brake spring6 Reduction rings7 Stator8 Rotor
9 Motor end cap, brake side10 Brake disc, also fan (shown: light conical
brake disc)11 Conical brake ring12 Brake cap13 Tensioning nut14 Tensioning screws15 Retaining ring
Executionwith conical brake disc with flat brake disc
Demag brake motor with squirrel-cage rotorKBA, KBF ranges
Fig. 2
41259744.eps
17161413
1211109876
54
32115
16 Flat brake disc, (shown: heavy flat brakedisc)
17 Flat brake ring
Fig. 1
3 Brake motors
KBA, KBF, KBS, SBA, SBSranges
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3.1 General information onDemag brake motors
Check unit for transport damage in the presence of an employee of the trucking com-pany, if the packing is in bad condition.
The shaft cannot be turned as rotor is braked during standstill.
The insulation resistance should be 1 000 W/V or higher.
If it is less because moisture has been absorbed due to unsuitable storage or due toother reasons, dry motor in a drying oven or by heating it with DC.Maximum temperature: 160 °C.
Important: Phase insulation of the motors is absolutely necessary in case of inverteroperation.
3.2 Inspection3.2.1 Mechanical
3.2.2 Electrical
1 The Demag brake motor is the combination of an electric motor and a spring-loaded brake in a common enclosure, operating on the sliding rotor principle. Itcan be supplied as a squirrel-cage motor or as a slip-ring motor. Characteristicof the brake motor is the cone shell shaped air gap between tapered rotor andstator.
Ranges KB., SB. comprise the following types:
Type: KBA Standard brake motor with squirrel-cage rotorKBF Brake motor with squirrel-cage rotor designed as travel motorKBS Torque motor with squirrel-cage rotorSBA Standard brake motor with slip-ring rotorSBS Torque motor with slip-ring rotor
2 With power off the motor is braked.
3 With power on, an axial component of the magnetic field produced by the coneshell shape of the air gap overcomes the force of the brake spring and draws therotor into the stator. This axial displacement is limited by the axial deep grooveball bearing.
The brake disc (10) designed as fan together with the brake ring (11) is releasedfrom the braking surface in the brake cap thus making the motor run up tospeed.
4 With power off – or in the case of mains failure – the motor is mechanicallybraked. Brake spring (5) pushes brake disc (10/16) fitted on shaft (1) with brakering (11/17) against the braking surface of brake cap (12).
5 Conical and flat brake rings (11/17) are armoured rubber rings to which the seg-mented or ring-shaped brake linings are vulcanized and which absorb shocksduring braking.
6 To obtain the brake torques indicated in the data lists as quickly as possible, runin brake lining by starting and stopping motor repeatedly before taking it intooperation.
A limited reduction of the brake torque can be obtained by fitting a weaker brakespring or – up to size 100 – by using a flat brake disc instead of a conical brakedisc.
7 Whereas the light brake disc allows a high number of starts and stops per hourfor general purpose drives, the starting and braking processes for travel drivesare damped by the heavy brake disc with its higher moment of inertia. Bothbrake discs can be fitted with a conical or a flat brake ring.
KBF travel motors are normally equipped with a heavy conical brake disc.
8 For the details concerning the additional equipment, as for example HBGL man-ual brake release attachment, LAG load lowering attachment, BLE brake releasedevice, EBLG electric brake release attachment and BEG brake torque setterattachment, see the corresponding operating instructions.
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3.3 Mounting3.3.1 Checking the state
3.3.2 Checking the site of installation
3.3.3 Alignment
3.3.4 Type of mounting
3.3.5 Oil-tight type
3.3.6 Outdoor mounting
3.3.7 Conversion of flange mountinginto foot mounting
Check unit for damage which has occured during transport or storage, such as e.g.corrosion, leakage, deformation or fracture.
Do not clean motors by means of pressurized air!
The standard motor is suitable for use under normal industrial conditions.
Ambient temperature: –20°C to +40°CSite altitude: up to 1000m above sea level
If the ambient temperature, atmosphere or air humidity deviate from these conditions,the motor may only be used with special equipment (see capacity plate).
The site of installation of the motor must be such that
• the circulating air for heat exchange can flow freely and heated air is not sucked inagain immediately.
• no residual material from production is collected on the motor, falls between thedrive elements or damages the sealing ring.
• the capacity plate is accessible.
Mount motor with feet on a plane surface which is free of vibrations. Avoid warpingwhen screwing down motor feet.
When fitting pinion drives or couplings the axial displacement of the shaft must not behindered. When the motor is running, the shaft is always in the same position. BeimAbschalten schiebt sie sich je nach Abnutzung des Bremsbelages um den Betrag derVerschiebung in den Motor.
Strictly observe mounting stamped on rating plate, which determines force of brakespring. When changing the type of mounting, be sure to order and fit a suitable brakespring, remembering that in a motor mounted in an inclined or vertical position theweight of the rotor plus possibly the weight of a coupling half or pulley, fitted to theshaft extension, must be compensated and that the upward or downward position ofthe shaft extension has to be taken into account.
The motors do not have condensation water drain holes. If required, such holes pro-vided with screw plugs can be supplied. In this case make sure when mounting themotor that the condensation water drain holes are situated at its lowest point. Whenchanging the mounting close the openings which are no more necessary so thatwater cannot enter the motor.
In the case of flange-mounted motors – oil-tight type – for direct fitting to gearboxes,flange and bearing are sealed against oil – the latter by means of a radial shaft seal.
We recommend to equip motors installed out of doors – especially those mounted inIM V 1 – with a protective roof. If required protective roofs for mounting IM V 1 canbe supplied.
KB 71 – 140 aluminium housing: Screw threaded inserts “Ensat” into the existingborings – with a recess of at least 0,5 mm.
KB 160 – 225 cast iron housing (or stator caps of SB 100 – 225 resp.):Thread exists.
Screw on motor feet and machine them according to the feet height(tolerance - 0,5 mm).
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3.4 Transmission elements3.4.1 Coupling, toothed wheel, belt,
pulleyCoupling: Only use flexible couplings allowing easy axial movement be-
tween the hubs of the coupling (for the displacement seetable 3.6.3).
Toothed wheel: The toothed wheels should have straight teeth.
Belt: The initial tension must not hinder the axial displacement of therotor.
Pulleys: Only change speed when the motor is running.
Remove anticorrosive agent on shaft ends and flange faces using a solvent.
The rotor of the motor has been balanced dynamically with half-fitted key.
Transmission elements such as couplings and pulleys must be balanced correspond-ingly.
When fitting or removing pinions, couplings and pulleys with appropriate device al-ways use tapped centre hole in shaft extension. Lightly grease shaft extension andhub bore. Do not hammer on the shaft extension of the motor when fitting transmis-sion elements.
3.4.2 Protection against rust
3.4.3 Balancing
3.4.4 Fitting device
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3.5.4 Trial run
Connections should be carried out by qualified personnel (VDE 0105) according tolocal regulations or according to VDE 0100 (specifications for the installation of powerplants with line voltages of up to 1000 V).
Observe rating plate data and compare line voltage!The motor must be operated according to the design specified on the rating plate.
In the case of a modification, for instance if the line voltage is increased from 460 V to480 V a correction of the brake spring might be necessary. Otherwise the wear of thedamper elements and the starting noise will increase.
To obtain clockwise rotation of the motor (looking on shaft extension) connect termi-nals U1, V1, W1 to line conductors L1, L2, L3 according to the circuit diagram in theterminal box, provided the line itself has clockwise rotation.
If the motor is equipped with PTC thermistors the corresponding cable leads areconnected to the separate terminals and marked with 101, 102, 103, 104, 111 and112. They should be connected after a short trial run.
In order to reverse the sense of rotation of the motor exchange two of the line con-ductors.
No special connections are necessary for the brake.
Threading of stud terminals in terminal box:
Motor size Stud
71, 80, 90 M 4100, 112, 125 M 5140, 160 M 6180, 200, 225 M 8
Use normal switchgear for starting and stopping Demag brake motors with one ex-ception:
Squirrel-cage motors are only permitted to be started with star delta starterswhen a weaker brake spring has been fitted, since otherwise the reduced axialthrust produced in the star position would not suffice for releasing the brake.
3.5 Connection3.5.1 Performance of connection
work
3.5.2 Switchgear
3.5.3 Protective measures
When starting the motor for trial, make sure the brake is properly released, i.e. thedisplacement of the rotor is sufficient, as otherwise the winding could burn out. Toobtain the full listed brake torque, as quickly as possible, run in brake lining by startingand stopping motor repeatedly before taking it into peration (see section 3.1, point 6).
During the first few hours of operation it may happen that the shaft extension and thedrive end stator cap warm up somewhat until the special bearing seals have been runin.
Before commissioning care must be taken that an additional protective measureaccording to VDE 0100 has been taken.
There is a terminal for the protective conductor marked according to DIN 40 011inside the terminal box.
An external earthing terminal can be fitted on request against extra charge.
In the case of protective earthing, the earthing terminal must have been connected.
If several protective measures are being used these must not render each other inef-fective.
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The Demag brake motors normally have 2 roller bearings and 1 axial deep-grooveball bearing. The rollers run directly on the hardened shaft. The grease filling of thebearings should be renewed every 10 000 operating hours. At the latest, however,the renewal of the lubricant should take place every 4 years. Under extremely severeoperating conditions, for instance in the case of a higher ambient temperature, it isrecommended to renew the lubricant according to the specific operating conditions.To effect this, the stator caps are removed and the bearings thoroughly washed witha washing liquid. The dried bearings are filled again preferably with Klüber PetamoGHY 133 N or with another anti-friction bearing grease of the quality shown in table3.6.1 (see below).
The bearings are sealed against dirt with special shaft seals. For the oil-tight type aradial shaft sealing ring similar to DIN 3760 with an absolutely smooth contact surfacehas been fitted into the flange type stator cap. When stripping the motor it is recom-mended to fit a new sealing ring. To effect this, follow the well-known fitting instruc-tions for radial shaft seals and make sure that the sealing lip of the sealing ring is notdamaged.
3.6 Maintenance3.6.1 Bearings
3.6.2 Slip-rings and brushes • The slip-rings of slip-ring motors must have a smooth surface free from hair linesand must run true to ensure a good contact of the brushes. Dust deposit shouldbe removed to avoid spark discharge. Rough slip-rings should be polished withcarborundum cloth that is pressed on by means of a wooden block with an exactlyfitting recess. Oval slip-rings should be precision machined on a lathe.
• Exchange of brushes: Lock home brush-holder arms by means of a latch-indevice.
• Disconnect cable leads from brush holders.
• Unscrew fastening nut from brush-stud carrier and take off brush system. Do notloosen brush holder fitted on brush stud in order to ensure that the position of thebrushes with respect to the slip-rings remains unchanged.
• Only use brushes of the same quality (see component parts list).
• Fit brushes and complete assembly in inverse order.
• To release the brush-holder arms lift latch-in device. During this make sure that thebrush-holder arm springs back slowly.
• Newly fitted brushes should be ground in with superfinishing carborundum cloth.
Table 3.6.1 Quality of the anti-friction bearing greaseserutarepmettneibmA
C°esaerggniraebnoitcirf-itnA
epyterutarepmetgnitarepO
C°
02- ot 04+gniraebnoitcirf-itnA
02-N3Kesaerg20515NID 041+ot02-
02- ot 08+gniraebnoitcirf-itnA
02-P3Kesaerg20515NID 061+ot02-
04- ot 08+gniraebnoitcirf-itnA
04-P3Kesaerg20515NID 061+ot04-
.tuptuorotomdetarehtrofC°04sierutarepmettneibmamumixameht1-43006NEotgnidroccA
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When working on the brake, loads must be prevented from imparting a torqueto the shaft.
Note: When using the motor as a main motor of a microspeed unit the brake hasto be adjusted according to “Operating instructions microspeed units,FG 06, FG 08, FG 10 ranges”.
1) Measure size of axial displacement lv.
2) Take off louver.
3) Take out screws (14) of adjusting nut.
4) Screw 2 screws (14) into the tapped holes of adjusting nut using them to press offbrake disc from adjusting nut.
5) Turn adjusting nut to the left until the desired decrease in displacement has beenreached.
3.7 Brakeadjustment
3.6.3 Brake As the brake ring wears off, the axial displacement increases from lv min to lv max (seetable 3.6.3).
It is absolutely necessary to check the brake at regular intervals and to adjust itbefore the max. axial displacement is reached.
Normally it is sufficient to adjust the brake during the usual routine motor inspection.In the case of heavy-duty reversing drives adjustment at regular intervals is advisable.
The axial rotor displacement from the running to the braked position can be deter-mined at the drive side shaft end or at the brake end when the louver is removed.This measurement should be made when the motor is a) at standstill and b) running(caution!).
From size 140, the path of displacement can be read in window in the brake cover.
6) Refit and tighten screws (14). For the tightening torques see table 4.1.
7) Screw on louver.
8) Start motor for trial and check axial displacement which should not be less thanlv min indicated in table 3.6.3.
The brake can be adjusted several times, until adjusting nut comes to rest againstretaining ring (15). Then the worn off brake ring should be replaced.
At least one reserve brake ring should always be kept in stock.
lv measured rotor displacement according to 1)
lv min min. displacement according to table 3.6.3
h thread pitch
h = 1,5 mm for sizes 71, 80, 90, 100,112
h = 2,0 mm for sizes 125, 140, 160, 180, 200, 225
Table 3.6.3 Axial displacement of the shaft
eziS sepyTSBS,ABS,SBK,FBK,ABK
tnemecalpsiD lvl v nim
mmlv xam
mm
09,08,17 5,1 0,3
211,001 8,1 5,3
041,521 0,2 0,4
522,002,081,061 3,2 5,4
h
l l left the to turnsof Number minvv −
=
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3.8 Exchange ofbrake ring
3.9 Exchange ofbrake spring
When working on the brake, loads must be prevented from imparting a torqueto the shaft.
1) Take off louver and brake cap.
2) Remove retaining ring (15).
3) Take out screws (14) of adjusting nut. Screw 2 screws into the tapped holes ofadjusting nut using them to press off brake disc from adjusting nut.
4) Unscrew adjusting nut and draw off brake disc (10/16).
5) Press worn brake ring (11/17) off brake disc.
6) Moisten rubber ring with water (never with oil!) and press new brake ring onbrake disc (10/16) by lightly knocking it with a vulcanite hammer around the en-tire circumference until it is flush with the brake disc (11/17). During this the brakering must not be deformed. It is advisable to use a suitable pressure plate forfitting the brake ring. The drawing of this pressure plate is available on request.
For higher demands, i.e.
• high stress exerted upon the brake• high braking accuracy• short running-in period for the brake
it is recommendable to replace the complete brake disc and/or to machine thebrake ring on a lathe after fitting. The angle of taper
• for sizes 71 - 200 is 21°
• for size 225 is 20°.
7) Slide brake disc (10/16) on shaft again.
8) Screw brake disc and adjusting nut firmly together with screws (14). For thetightening torque see table 4.1.
9) Fit retaining ring (15) on shaft end.
10) Fit brake cap and louver.
11) Start motor for trial and check axial displacement. If this is less than lv min, asindicated in table 3.6.3 readjust brake according to section 3.7.
12) To obtain the full brake torque as quickly as possible run in brake lining by start-ing and stopping motor repeatedly.
1) Take off drive end stator cap (2).
In the case of SB 100 – 140 slip-ring motors take account of section 4.2!
2) Compress brake spring (5) by exerting pressure on thrust ring (4).
3) Remove retaining ring (3) from shaft and take tension out of brake spring bygradually releasing the pressure exerted on thrust ring.
4) Remove thrust ring (4) and dished washer pack from shaft.
5) Exchange brake spring and, if necessary, the adaptor washer.
6) Compress brake spring with dished washer pack and thrust ring (3) and refitretaining ring.
Make sure that spring ring fits properly into groove of shaft!
7) Refit drive end stator cap (2).
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3.10.2 SB 100 – 140 slip-ring motors
3.10.3 KB 160 – 225 squirrel-cagemotorsSB 160 – 225 slip-ring motors
3.10 Moving terminal box
3.10.1 KB 71 – 140 squirrel-cagemotors
Where the mounting allows it the terminal box sitting on drive end stator cap (2) canbe arranged on the right, on the left and on top of the motor.
1) Open terminal box and disconnect stator leads from terminals.
2) Take off drive end stator cap (2).
3) Bring stator leads to the desired terminal box position.
4) Refit stator end cap (2) with the cable leads introduced into the terminal box.
5) Connect cable leads with terminals according to circuit diagram and close termi-nal box.
In the case of foot mountings the terminal box mounted on the drive end stator capcan be moved to the right-hand side or to the left-hand side, in the case of flangemountings it can also be positioned on top (without suspension eye) or at the bottomof the motor.
The brush system is on the terminal box side. On request it can also be mounted onthe opposite side.
1) Open terminal box, disconnect cable leads from terminals.
2) Turn stator cap through 90° only for terminal box position on top or at the bot-tom of the motor.
3) Move terminal box.
4) Move brush system.
5) Bring cable leads to the new terminal box position and connect with terminalsaccording to the circuit diagram.
6) Close terminal box and service openings.
Moving terminal box from the right-hand side to the left-hand side.
1) Take off terminal box.
2) Draw back cable leads of winding from cable opening – if necessary lengthencable leads – and bring cable leads to the other side.
3) Provide cable opening and tapped holes for bottom part of terminal box on theopposite side of the stator. Fit cable gland (plastic) into new cable opening.
4) Seal cable opening and tapped holes on the right-hand side suitably.
5) Refit terminal box and connect cable leads with terminals according to circuitdiagram and close terminal box.
6) If necessary move brush system, see section 3.10.2.
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Check and if necessary adjust air gap after each regular motor overhaul and also aftereach exchange of drive end stator cap, stator, rotor or dished washer pack, the toler-ances of which influence the air gap value.
A too wide air gap means reduced motor output and an excessive temperature rise, atoo narrow air gap makes the rotor graze against the stator and leads to destruction.
In the case of slip-ring motors SB take account of section 4.2!
1) Screw drive end stator cap (2) complete with bearing and seals to stator (7).
2) Place stator on a suitable support with the still open end showing upwards, tak-ing care that there is sufficient space below for the shaft extension which willprotrude from the stator cap.
3) Fit on shaft: dished washer pack, thrust ring (4) and spring ring (3). To allow com-pensation of manufacturing tolerances, the thrust ring is supplied in differentthicknesses. First select a medium thickness. Fit thrust ring with chamfered sidetowards retaining ring.
4) Insert rotor, fitted as above, into stator and lower carefully, until thrust ring buttsagainst thrust bearing.
5) Introduce three feeler gauges, having the correct air gap size, at 120° from eachother into the air gap between stator and rotor core for their entire length. The airgap is correct, when all three feeler gauges can be moved up and down withlittle effort.
When air gap is too wide, fit a thinner thrust ring. When it is too narrow, a thickerthrust ring should be fitted. Check air gap once more.
6) Take rotor out again and remove retaining ring, thrust ring and dished washerpack. Fit any necessary adaptor rings, brake spring and the removed parts onshaft.
Take care that retaining ring fits properly into the groove. After being re-leased the brake spring presses the thrust ring against the retaining ring.
7) Complete assembly of motor according to figure 2 (chapter 3) or according tothe component parts list.
3.11 Adjusting the air gap
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Table 3.11
The screws of Demag brake motors have to be tightened according to the tighteningtorques indicated in table 4.1. These tightening torques are also valid for screws witha higher strength.
4 Mounting instructions4.1 Tightening torques
When mounting or dismantling SB slip-ring motors the brush holder arms have to belocked home by means of the latch-in device. The brush holder arms can be releasedagain by lifting the latch-in device. During this make sure that the brush holder armsprings back slowly.
4.2 Mounting, dismantling of SBslip-ring motors
Table 4.1
seguagreleeffonoitcelesdnaseulavpagriatcerroC
rotoM eziS 17 08 09 001 211 521 041 061 081 002 522
epyT pagriA d
SBK,ABK δ nim 1) mm 52,0 52,0 03,0 03,0 53,0 53,0 04,0 54,0 05,0 05,0 55,0
SBS,ABS δ xam mm 03,0 03,0 53,0 53,0 54,0 54,0 05,0 55,0 06,0 06,0 56,0
FBK δ nim 1) mm 03,0 03,0 04,0 04,0 54,0 54,0 05,0 - - - -
δ xam mm 53,0 53,0 05,0 05,0 55,0 55,0 06,0 - - - -
eguagreleeF
eziS
052x3x52,0 X X
052x3x03,0 X X X X
003x3x53,0 X X X X X
003x3x04,0 X X X X X
003x3x54,0 X X X
003x3x05,0 X X X
003x3x55,0 X X X
003x5x53,0 X
003x5x04,0 X X
003x5x54,0 X X X
003x5x05,0 X X X X X X
053x5x55,0 X X X X X X
053x5x06,0 X X X X X X
053x5x56,0 X X X X
053x5x07,0 X X X
teseguagreleeF 48...001 051 051 151 151 251 351 451 551 651 651 651
1 pagria,kcaprehsawdehsidwenagnittifnehW) δ nim ,mm50,0ybdeasaercniebtsah.snoitarepoemosretfasesaercedkcaprehsawdehsidehtfossenkcihtehtecnis
swercsrofseuqrotgninethgiT
41BMIgnitnuomegnalfrof2196NIDot.ccasallewsa219NIDot.ccaswercspacdaehtekcosnogaxehroF
eziswercS 5M 6M 8M 01M 21M 61M
euqrotgninethgiT mN5,7-0,6 mN41-5,01 mN03-52 mN06-05 mN001-68 mN552-512
5BMIgnitnuomegnalffoesacehtnisallewsagnitnuomtooffoesacnippiR-subreVswercsgnikcol-flesroF
eziswercS 5M 6M 8M 01M 21M 61M
euqrotgninethgiTnoritsacfoesaceht mN5,7 mN41 mN03 nmN56 mN001 mN072
euqrotgninethgiTtsac-eidfoesaceht
muinimula mN9 mN81 mN54 mN57 – –
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5 Mains connection
Check voltage and set terminals accordingly!
When leaving our works, the terminals of our motors are unconnected.
6.1 Three-phase rotorfor 2 and 4-pole motorsfor pole-changing motors (only high speed)for 6-pole SB 160 – 225 motors
6.2 Two-pole rotorfor 6-pole SB 100 – 140 motors
Connection to the starter or rotor controller resp. Connection to the starter or rotor controller resp.
6 Rotor connection in the case of slip-ring motors
5.1 One-speed connection 5.3 Connection with two separate windings for twospeeds and one voltage
5.2 Dahlander connectionfor 2 speeds of a 1 : 2 ratio
5.4 Connection with one winding for one speedand two voltages of a 1 : 2 ratio
U2 V2W2
L3
V1 W1U1
L2L1 L3L2L1
U2 V2W2
V1 W1U1
L3L2L141492844.eps 41492944.eps
D connection Y connection
2V 2W2U
1V 1W1U
L3L2L141493044.eps
2V 2W2U
1V 1W1U
L3L2L141493144.eps
Y connectionLow speed
Y connectionHigh speed
2V 2W2U
1V 1W1U
L3L2L141493044.eps
2V 2W2U
1V 1W1U
L3L2L1
41493244.eps
D connectionLow speed
Dahlander connected (single-winding) motors aredesigned for one line voltage only.
W5W1
L3L2L1
V5V1
U5U1
U2 V2 W2
W5W1
L3L2L1
V5V1
U5U1
41493344.eps
V2V5
W1V1U1
U2U5
W2W5
L3L2L1 L3L2L141493444.eps
YY connectionHigh speed
YY connectionLow voltage
Y connectionHigh voltage
K
L
M
41493544.eps
K L M
41493644.eps
K
Q
L
41493744.eps
K Q L
41493844.eps
rofrotoM D - rofnoitcennocfoylppusrewop
rofnoitcennoc-Yfoylppusrewop
V032/231 V231 V032V004/032 V032 V004
V005 V005V006 V006V096 V096
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Ident. no.
Page 1
Issue 0697 EN
1 Page(s)
Class. no.
Reproduction in whole or in part only with prior consent of Mannesmann Dematic AG, D-58286 WetterSubject to alteration
715 IS 911
D-58286 Wetter
205 541 44
# = Modifications compared to previous issue
i.V. Ropelius ppa. Peters
Technik und Entwicklung Vertrieb
Motoren Antriebstechnik
7550 Normung
Hereby we,
Mannesmann Dematic AGAntriebstechnik,
that the product
Demag AC brake motor
of the
KB, KD, KM, KLA 132-225
type of serial design, with or without the relevant gearbox, has been declared in con-formity with the provisions of the following relevant regulations:
EC EMV Directive 89/336/EW
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 ofvibration severity
EN 60034-18-1 Functional assessment of insulation systems
EN 60529 Types of enclosure (IP Code)
Wetter, 11 June 1997
Place and date of issue
EC – declaration of conformityDemag AC brake motor
in accordance with EC directives 89/336/EEC, Annex I,and 73/23/EEC, Annex III
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8Ident. no.
Page 1
EN
1 page(s)
Class. no.
Reproduction in whole or in part only with prior consent of Mannesmann Dematic AG, D-58286 WetterSubject to alteration
715 IS 910
204 911 44
EC manufacturer’s declarationDemag brake motors
in accordance with EC directive 89/392/EEC, Annex IIB
i.V. Ropelius ppa. Peters
Technik und Entwicklung Vertrieb
Motoren Antriebstechnik
7550 Normung
Issue 0797
Hereby we,
Mannesmann Dematic AGAntriebstechnik,
declare that the product
Demag brake motor
series
KL, SB
of serial design is intended to be incorporated into machinery and that the machinerymust not be put into service until the machinery into which this product is to be incor-porated has been declared in conformity with the provisions of the following relevantregulations:
EC Machinery Directive 89/392/EEC
amended by 91/368/EEC
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 292 Safety of Machinery
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 ofvibration severity
EN 60034-18-1 Functional assessment of insulation systems
EN 60529 Types of enclosure (IP Code)
Wetter, 23 July 1997
Place and date of issue
# = Modifications comparedto previous issue
D-58286 Wetter
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rinte
d in
Ger
man
y M
BR
/129
8/6T
Reproduction in whole or in part only with prior consent of Mannesmann Dematic AG, D-58286 Wetter Subject to alteration
