Operating instructions

Brake motors, KBA, KBF, KBS, SBA, SBS ranges

21431844.p65/0898

41239944.eps

0898 EN

214 318 44

720 IS 911 1

Manufacturer

Mannesmann Dematic AG

Further documents

Contents

Description brake motors

KB, SB brake motors
FG microspeed units

203 255 44

714 IS 911

Data Brake motor dimensions

KBA, KBL squirrel-cage motors, 400 V

201 620 84

714 IS 911

Data Brake motor dimensions

KBV, KBF travel motors, 400 V
SBA slip-ring motors, 400 V
KBZ, KBS, SBS torque motors, 400 V

201 619 84

714 IS 911

Squirrel-cage rotor brake motors

KDF/KMF/KBV/KBF
for travel applications

202 549 44

714 IS 911

Data
FG microspeed units

200 185 84

714 IS 911

Microspeed unit dimensions

FG 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

Foreword

0.1
0.2
0.3
0.4
0.5

Copyright
After-sales service
Guarantee
Limitations of liability
Definitions

4
4
5
5
6

Safety

1.1
1.2
1.3
1.4

Symbols
Intended use
Prohibited practises, improper use
Safety instructions

7
7
7
8
21431844.p65/0898

P.O. Box 67, D-58286 Wetter

Telephone (+49 2335) 92-0, Telefax (+49 2335) 927676
Internet http://www.dematic.com

21431844.p65/0898

Receiving, transport and storage

2.1
2.2
2.3

Receiving
Transport
Storage

9
9
9

Brake motors
KBA, KBF, KBS, SBA, SBS ranges

10

3.1
3.2
3.2.1
3.2.2
3.3
3.3.1
3.3.2
3.3.3
3.3.4
3.3.5
3.3.6
3.3.7
3.4
3.4.1
3.4.2
3.4.3
3.4.4
3.5
3.5.1
3.5.2
3.5.3
3.5.4
3.6
3.6.1
3.6.2
3.6.3
3.7
3.8
3.9
3.10
3.10.1
3.10.2
3.10.3
3.11

General information on Demag brake motors

Inspection
Mechanical
Electrical
Mounting
Checking the state
Checking the site of installation
Alignment
Type of mounting
Oil-tight type
Outdoor mounting
Conversion of flange mounting into foot mounting
Transmission elements
Coupling, toothed wheel, belt, pulley
Protection against rust
Balancing
Fitting device
Connection
Performance of connection work
Switchgear
Protective measures
Trial run
Maintenance
Bearings
Slip-rings and brushes
Brake
Brake adjustment
Exchange of brake ring
Exchange of brake spring
Moving terminal box
KB 71 140 squirrel-cage motors
SB 100 140 slip-ring motors
KB 160 225 squirrel-cage motors, SB 160 225 slip-ring motors
Adjusting the air gap

11
11
11
11
12
12
12
12
12
12
12
12
13
13
13
13
13
14
14
14
14
14
15
15
15
16
16
17
17
18
18
18
18
19

Mounting instructions

20

4.1
4.2

Tightening torques
Mounting, dismantling of SB slip-ring motors

20
20

Mains connection

21

5.1
5.2
5.3
5.4

One-speed connection
Dahlander connection for 2 speeds of a 1:2 ratio
Connection with 2 separate windings for 2 speeds and one voltage
Connection with one winding for 1 speed and two voltages
of a 1:2 ratio

21
21
21
21

Rotor connection

21

6.1
6.2

Three-phase rotor
Two-phase rotor

21
21

EC conformity declaration

22

EC manufacturers declaration

23

Foreword

You have purchased a Mannesmann Dematic product. This equipment was manufactured in accordance with state-of-the-art engineering principles.
These operating instructions are designed to provide the operator with appropriate
instructions for safe and correct operation and to facilitate maintenance.
Every individual given the task of transporting, installing, commissioning, operating,
maintaining and repairing our KB., SB. motors and additional equipment must have
read and understood
the operating instructions
the safety regulations and
safety instructions in the individual chapters and sections.
The operating instructions must be available to the operating personnel at all times in
order to prevent operating errors and to ensure smooth and trouble-free operation of
our products.

0.1 Copyright

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 Mannesmann Dematic. 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 compensatory damages. All industrial rights reserved.

For technical information on Mannesmann Dematic 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.

21431844.p65/0898

0.2 After-sales service

0.3 Guarantee

These operating instructions 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 to
Mannesmann 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 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
Mannesmann Dematic.

0.4 Limitations of liability

All technical information, data and instructions for operation contained in these operating instructions were up-to-date on going to print and are compiled on the basis of
our experience and to the best of our knowledge.
We reserve the right to incorporate technical modifications within the scope of further
development of this brake motors, KBA, KBF, KBS, SBA, SBS ranges - which are the
subject of these operating instructions.
Therefore, no claims can be derived from the information, illustrations and descriptions contained in these operating instructions.
We assume no liability for damage and malfunctions caused as a result of operating
errors, noncompliance with these operating instructions or inappropriate repairs.

21431844.p65/0898

We expressly point out that only Mannesmann Dematic spare parts and accessories
approved 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 not
been approved and unauthorized modification and conversion of the hoist unit are not
permitted and exempt Mannesmann Dematic from any liability for damages resulting
therefrom.
With the exclusion of any further claims, Mannesmann Dematic is liable for any faults
or omissions on our part within the scope of the warranty obligations entered into in
the original contract. Claims for damages are excluded, irrespective of the legal reason from which such claims are derived.
Translations are done to the best of our knowledge. We are unable to accept liability
for translation errors, irrespective of whether the text is translated by us or on our
behalf. The original text is definitive alone.
The descriptions and illustrations contained in this documentation do not necessarily
correspond to the scope of delivery or any subsequent spare part delivery. The drawings and illustrations are not to scale.
Only documentation belonging to the actual order is valid.

0.5 Definitions

Owner
Owners (employer, company) are defined as persons who own the product and who
use it appropriately or allow it to be operated by suitable persons.
Operating personnel
Operating personnel are defined as persons assigned by the owner of the product to
carry out special tasks such as installation, operation, setting-up, maintenance including cleaning, fault elimination and transportation of the product.
Specialist personnel
Specialist personnel are defined as persons assigned by the owner to carry out specific tasks.
Qualified personnel (electrician)
Qualified personnel (electricians) are defined as persons, who, owing to their technical training, knowledge and experience as well as knowledge of the relevant
standards, are able to assess the tasks given to them and identify potential hazards.
Trained person
Trained persons are defined as persons who have been instructed and trained for
the tasks assigned to them and on the possible hazards resulting from incorrect
handling and who have been informed about the required protective devices, protective measures, relevant regulations, accident prevention regulations and operating conditions and who have proven their qualifications.
Experienced technician

21431844.p65/0898

Experienced technicians are defined as persons, who, owing to their technical

training and experience, have sufficient knowledge of the product and are familiar
with the relevant national industrial safety regulations, 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 KB., SB. motors.

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 including
the power supply.
In addition to the safety instructions, observe all general safety regulations and factoryspecific accident prevention regulations 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 disconnected.
Operating hazard for the installation
This symbol in the operating instructions indicates all warnings which, if not complied
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,

improper use

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.:
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.

21431844.p65/0898

Safety devices must not be rendered inoperable or modified or used in any way other
than that for which they have been designed.

1.4 Safety instructions

The relevant national accident prevention regulations and the general safety conditions must always be observed when our products are operated in order to avoid
accidents and damage to machinery. If the safety instructions given in these operating instructions are not observed in any way, personal injury or even death can result.
Dangerous voltage!
Motors are connected to a mains power supply. Any contact with live parts can lead
to very serious injury or even death.

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 (electrician),
if you are not under the influence of drugs, alcohol or medication that can adversely affect your ability to react,
if the general accident prevention, operating and installation regulations
(e.g. DIN VDE 0100/0113) have been observed.

Additional safety instructions

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,

21431844.p65/0898

using genuine spare parts.

Receiving, transport and storage

2.1 Receiving

The scope of delivery is specified in the shipping papers. Check the delivery immediately on receipt to ensure that it is complete and examine it for damage caused in
transit. If necessary, a damage report must be made out in the presence of the transport contractors representative as otherwise it will not be possible to rectify the damage at no cost to you.

2.2 Transport

The drive is supplied made up into one unit. Additional equipment may be supplied in
separate packaging.
The drive is packed depending on the transport method and its weight. Unless otherwise agreed in the purchase contract, the packaging corresponds to the packaging
guidelines of Mannesmann Dematic, ident no. 236 070 44.
Symbols used on the packing

This way up

Top-heavy

Fragile

No hooks

Keep dry

Attach sling here

Protect from heat

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 guaranteed for a period of 6 months. The guarantee period begins on the day the unit is
delivered.
Contact Mannesmann Dematic in Wetter, Germany, if geared motors are to be stored
for periods of longer than 6 months.

21431844.p65/0898

Important! Motors may otherwise be damaged.

Brake motors
KBA, KBF, KBS, SBA, SBS
ranges

Fig. 1

41415444.eps

Execution
with conical brake disc

Fig. 2
1

5
4

10 11

with flat brake disc

12

14
13 15

16

17

41259744.eps

Demag brake motor with squirrel-cage rotor

10

1
2
3
4
5
6
7
8

Shaft
Motor end cap, drive side
Spring ring
Thrust ring
Brake spring
Reduction rings
Stator
Rotor

9
10
11
12
13
14
15

Motor end cap, brake side

Brake disc, also fan (shown: light conical
brake disc)
Conical brake ring
Brake cap
Tensioning nut
Tensioning screws
Retaining ring

16
17

Flat brake disc, (shown: heavy flat brake

disc)
Flat brake ring

21431844.p65/0898

KBA, KBF ranges

3.1 General information on

Demag brake motors

The Demag brake motor is the combination of an electric motor and a springloaded brake in a common enclosure, operating on the sliding rotor principle. It
can be supplied as a squirrel-cage motor or as a slip-ring motor. Characteristic
of the brake motor is the cone shell shaped air gap between tapered rotor and
stator.
Ranges KB., SB. comprise the following types:
Type:

KBA
KBF
KBS
SBA
SBS

Standard brake motor with squirrel-cage rotor

Brake motor with squirrel-cage rotor designed as travel motor
Torque motor with squirrel-cage rotor
Standard brake motor with slip-ring rotor
Torque motor with slip-ring rotor

With power off the motor is braked.

With power on, an axial component of the magnetic field produced by the cone
shell shape of the air gap overcomes the force of the brake spring and draws the
rotor into the stator. This axial displacement is limited by the axial deep groove
ball bearing.
The brake disc (10) designed as fan together with the brake ring (11) is released
from the braking surface in the brake cap thus making the motor run up to
speed.

With power off or in the case of mains failure the motor is mechanically
braked. Brake spring (5) pushes brake disc (10/16) fitted on shaft (1) with brake
ring (11/17) against the braking surface of brake cap (12).

Conical and flat brake rings (11/17) are armoured rubber rings to which the segmented or ring-shaped brake linings are vulcanized and which absorb shocks
during braking.

To obtain the brake torques indicated in the data lists as quickly as possible, run
in brake lining by starting and stopping motor repeatedly before taking it into
operation.
A limited reduction of the brake torque can be obtained by fitting a weaker brake
spring or up to size 100 by using a flat brake disc instead of a conical brake
disc.

Whereas the light brake disc allows a high number of starts and stops per hour
for general purpose drives, the starting and braking processes for travel drives
are damped by the heavy brake disc with its higher moment of inertia. Both
brake discs can be fitted with a conical or a flat brake ring.
KBF travel motors are normally equipped with a heavy conical brake disc.

For the details concerning the additional equipment, as for example HBGL manual brake release attachment, LAG load lowering attachment, BLE brake release
device, EBLG electric brake release attachment and BEG brake torque setter
attachment, see the corresponding operating instructions.

3.2 Inspection
3.2.1 Mechanical

Check unit for transport damage in the presence of an employee of the trucking company, if the packing is in bad condition.
The shaft cannot be turned as rotor is braked during standstill.

21431844.p65/0898

3.2.2 Electrical

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 to
other 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 inverter
operation.
11

3.3 Mounting
3.3.1 Checking the state

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!

3.3.2 Checking the site of installation

The standard motor is suitable for use under normal industrial conditions.
Ambient temperature:
Site altitude:

20C to +40C
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 in
again immediately.
no residual material from production is collected on the motor, falls between the
drive elements or damages the sealing ring.
the capacity plate is accessible.
3.3.3 Alignment

Mount motor with feet on a plane surface which is free of vibrations. Avoid warping
when screwing down motor feet.
When fitting pinion drives or couplings the axial displacement of the shaft must not be
hindered. When the motor is running, the shaft is always in the same position. Beim
Abschalten schiebt sie sich je nach Abnutzung des Bremsbelages um den Betrag der
Verschiebung in den Motor.

3.3.4 Type of mounting

Strictly observe mounting stamped on rating plate, which determines force of brake
spring. When changing the type of mounting, be sure to order and fit a suitable brake
spring, remembering that in a motor mounted in an inclined or vertical position the
weight of the rotor plus possibly the weight of a coupling half or pulley, fitted to the
shaft extension, must be compensated and that the upward or downward position of
the shaft extension has to be taken into account.
The motors do not have condensation water drain holes. If required, such holes provided with screw plugs can be supplied. In this case make sure when mounting the
motor that the condensation water drain holes are situated at its lowest point. When
changing the mounting close the openings which are no more necessary so that
water cannot enter the motor.

3.3.5 Oil-tight type

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.

3.3.6 Outdoor mounting

We recommend to equip motors installed out of doors especially those mounted in

IM V 1 with a protective roof. If required protective roofs for mounting IM V 1 can
be supplied.

3.3.7 Conversion of flange mounting

into foot mounting

KB 71 140 aluminium housing: Screw threaded inserts Ensat into the existing
borings 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.

12

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Screw on motor feet and machine them according to the feet height
(tolerance - 0,5 mm).

3.4 Transmission elements

3.4.1 Coupling, toothed wheel, belt,
pulley

Coupling:

Only use flexible couplings allowing easy axial movement between the hubs of the coupling (for the displacement see
table 3.6.3).

Toothed wheel:

The toothed wheels should have straight teeth.

Belt:

The initial tension must not hinder the axial displacement of the
rotor.

Pulleys:

Only change speed when the motor is running.

3.4.2 Protection against rust

Remove anticorrosive agent on shaft ends and flange faces using a solvent.

3.4.3 Balancing

The rotor of the motor has been balanced dynamically with half-fitted key.
Transmission elements such as couplings and pulleys must be balanced correspondingly.

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3.4.4 Fitting device

When fitting or removing pinions, couplings and pulleys with appropriate device always use tapped centre hole in shaft extension. Lightly grease shaft extension and
hub bore. Do not hammer on the shaft extension of the motor when fitting transmission elements.

13

3.5 Connection
3.5.1 Performance of connection
work

Connections should be carried out by qualified personnel (VDE 0105) according to

local regulations or according to VDE 0100 (specifications for the installation of power
plants 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 to
480 V a correction of the brake spring might be necessary. Otherwise the wear of the
damper elements and the starting noise will increase.
To obtain clockwise rotation of the motor (looking on shaft extension) connect terminals U1, V1, W1 to line conductors L1, L2, L3 according to the circuit diagram in the
terminal box, provided the line itself has clockwise rotation.
If the motor is equipped with PTC thermistors the corresponding cable leads are
connected to the separate terminals and marked with 101, 102, 103, 104, 111 and
112. 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 conductors.
No special connections are necessary for the brake.
Threading of stud terminals in terminal box:

3.5.2 Switchgear

Motor size

Stud

71, 80, 90
100, 112, 125
140, 160
180, 200, 225

M4
M5
M6
M8

Use normal switchgear for starting and stopping Demag brake motors with one exception:
Squirrel-cage motors are only permitted to be started with star delta starters
when a weaker brake spring has been fitted, since otherwise the reduced axial
thrust produced in the star position would not suffice for releasing the brake.

3.5.3 Protective measures

Before commissioning care must be taken that an additional protective measure

according to VDE 0100 has been taken.
There is a terminal for the protective conductor marked according to DIN 40 011
inside 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 ineffective.

3.5.4 Trial run

When starting the motor for trial, make sure the brake is properly released, i.e. the
displacement of the rotor is sufficient, as otherwise the winding could burn out. To
obtain the full listed brake torque, as quickly as possible, run in brake lining by starting
and stopping motor repeatedly before taking it into peration (see section 3.1, point 6).

14

21431844.p65/0898

During the first few hours of operation it may happen that the shaft extension and the
drive end stator cap warm up somewhat until the special bearing seals have been run
in.

3.6 Maintenance
3.6.1 Bearings

The Demag brake motors normally have 2 roller bearings and 1 axial deep-groove
ball bearing. The rollers run directly on the hardened shaft. The grease filling of the
bearings 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 severe
operating conditions, for instance in the case of a higher ambient temperature, it is
recommended to renew the lubricant according to the specific operating conditions.
To effect this, the stator caps are removed and the bearings thoroughly washed with
a washing liquid. The dried bearings are filled again preferably with Klber Petamo
GHY 133 N or with another anti-friction bearing grease of the quality shown in table
3.6.1 (see below).
The bearings are sealed against dirt with special shaft seals. For the oil-tight type a
radial shaft sealing ring similar to DIN 3760 with an absolutely smooth contact surface
has been fitted into the flange type stator cap. When stripping the motor it is recommended to fit a new sealing ring. To effect this, follow the well-known fitting instructions for radial shaft seals and make sure that the sealing lip of the sealing ring is not
damaged.
Table 3.6.1 Quality of the anti-friction bearing greases
Ambient temperature
C

Anti-friction bearing grease

type

Operating temperature
C

-20 to +40

Anti-friction bearing
grease K3N-20

DIN 51502

-20 to +140

-20 to +80

Anti-friction bearing
grease K3P-20

DIN 51502

-20 to +160

-40 to +80

Anti-friction bearing
grease K3P-40

DIN 51502

-40 to +160

According to EN 60034-1 the maximum ambient temperature is 40 C for the rated motor output.

3.6.2 Slip-rings and brushes

The slip-rings of slip-ring motors must have a smooth surface free from hair lines
and must run true to ensure a good contact of the brushes. Dust deposit should
be removed to avoid spark discharge. Rough slip-rings should be polished with
carborundum cloth that is pressed on by means of a wooden block with an exactly
fitting recess. Oval slip-rings should be precision machined on a lathe.
Exchange of brushes:

Lock home brush-holder arms by means of a latch-in

device.

Disconnect cable leads from brush holders.

Unscrew fastening nut from brush-stud carrier and take off brush system. Do not
loosen brush holder fitted on brush stud in order to ensure that the position of the
brushes 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 the
brush-holder arm springs back slowly.

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Newly fitted brushes should be ground in with superfinishing carborundum cloth.

15

3.6.3 Brake

As the brake ring wears off, the axial displacement increases from lv min to l v max (see
table 3.6.3).
It is absolutely necessary to check the brake at regular intervals and to adjust it
before 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 determined 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.

Table 3.6.3

Axial displacement of the shaft

Types
KBA, KBF, KBS, SBA, SBS

Size

Displacement l v

71, 80, 90

3.7 Brake
adjustment

l v min
mm

l v max
mm

1,5

3,0

100, 112

1,8

3,5

125, 140

2,0

4,0

160, 180, 200, 225

2,3

4,5

When working on the brake, loads must be prevented from imparting a torque
to the shaft.
Note: When using the motor as a main motor of a microspeed unit the brake has
to be adjusted according to Operating instructions microspeed units,
FG 06, FG 08, FG 10 ranges.
1) Measure size of axial displacement l v .
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 off
brake disc from adjusting nut.
5) Turn adjusting nut to the left until the desired decrease in displacement has been
reached.
Number of turns to the left =

l v l vmin
h

lv

measured rotor displacement according to 1)

l v min

min. displacement according to table 3.6.3

thread pitch
h = 1,5 mm for sizes
h = 2,0 mm for sizes

71, 80, 90, 100, 112

125, 140, 160, 180, 200, 225

6) Refit and tighten screws (14). For the tightening torques see table 4.1.
8) Start motor for trial and check axial displacement which should not be less than
l v min indicated in table 3.6.3.
The brake can be adjusted several times, until adjusting nut comes to rest against
retaining ring (15). Then the worn off brake ring should be replaced.
At least one reserve brake ring should always be kept in stock.
16

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7) Screw on louver.

3.8 Exchange of
brake ring

When working on the brake, loads must be prevented from imparting a torque
to 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 of
adjusting 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 on
brake disc (10/16) by lightly knocking it with a vulcanite hammer around the entire circumference until it is flush with the brake disc (11/17). During this the brake
ring must not be deformed. It is advisable to use a suitable pressure plate for
fitting 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 the
brake ring on a lathe after fitting. The angle of taper
for sizes
for size

71 - 200 is

21

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 the
tightening 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 l v min, as
indicated 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 starting and stopping motor repeatedly.

3.9 Exchange of
brake spring

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 by
gradually 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 refit
retaining ring.
Make sure that spring ring fits properly into groove of shaft!

21431844.p65/0898

7) Refit drive end stator cap (2).

17

3.10 Moving terminal box

3.10.1 KB 71 140 squirrel-cage
motors

Where the mounting allows it the terminal box sitting on drive end stator cap (2) can
be 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 terminal box.

3.10.2 SB 100 140 slip-ring motors

In the case of foot mountings the terminal box mounted on the drive end stator cap
can be moved to the right-hand side or to the left-hand side, in the case of flange
mountings it can also be positioned on top (without suspension eye) or at the bottom
of the motor.
The brush system is on the terminal box side. On request it can also be mounted on
the opposite side.

18

Open terminal box, disconnect cable leads from terminals.

2)

Turn stator cap through 90 only for terminal box position on top or at the bottom of the motor.

3)

Move terminal box.

4)

Move brush system.

5)

Bring cable leads to the new terminal box position and connect with terminals
according 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 lengthen
cable leads and bring cable leads to the other side.

3)

Provide cable opening and tapped holes for bottom part of terminal box on the
opposite 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 circuit
diagram and close terminal box.

6)

If necessary move brush system, see section 3.10.2.

21431844.p65/0898

3.10.3 KB 160 225 squirrel-cage

motors
SB 160 225 slip-ring motors

1)

3.11 Adjusting the air gap

Check and if necessary adjust air gap after each regular motor overhaul and also after
each exchange of drive end stator cap, stator, rotor or dished washer pack, the tolerances of which influence the air gap value.
A too wide air gap means reduced motor output and an excessive temperature rise, a
too 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, taking care that there is sufficient space below for the shaft extension which will
protrude from the stator cap.

3)

Fit on shaft: dished washer pack, thrust ring (4) and spring ring (3). To allow compensation of manufacturing tolerances, the thrust ring is supplied in different
thicknesses. First select a medium thickness. Fit thrust ring with chamfered side
towards retaining ring.

4)

Insert rotor, fitted as above, into stator and lower carefully, until thrust ring butts
against thrust bearing.

5)

Introduce three feeler gauges, having the correct air gap size, at 120 from each
other into the air gap between stator and rotor core for their entire length. The air
gap is correct, when all three feeler gauges can be moved up and down with
little effort.
When air gap is too wide, fit a thinner thrust ring. When it is too narrow, a thicker
thrust ring should be fitted. Check air gap once more.

6)

Take rotor out again and remove retaining ring, thrust ring and dished washer
pack. Fit any necessary adaptor rings, brake spring and the removed parts on
shaft.
Take care that retaining ring fits properly into the groove. After being released the brake spring presses the thrust ring against the retaining ring.

21431844.p65/0898

7)

Complete assembly of motor according to figure 2 (chapter 3) or according to

the component parts list.

19

Table 3.11

Correct air gap values and selection of feeler gauges

M ot or

Size

Type

Air gap d

71

80

90

100

112

125

140

160

180

200

225

KBA, KBS

min 1)

SBA, SBS

max

mm

0,25

0,25

0,30

0,30

0,35

0,35

0,40

0,45

0,50

0,50

0,55

mm

0,30

0,30

0,35

0,35

0,45

0,45

0,50

0,55

0,60

0,60

KBF

0,65

min 1)

mm

0,30

0,30

0,40

0,40

0,45

0,45

0,50

max

mm

0,35

0,35

0,50

0,50

0,55

0,55

0,60

Feeler gauge
Size
0,25x3x250

0,30x3x250

0,35x3x300

0,40x3x300

0,45x3x300

0,50x3x300

0,55x3x300

0,35x5x300

0,40x5x300

0,45x5x300

0,50x5x300

0,55x5x350

0,60x5x350

0,65x5x350

156

156

156

0,70x5x350
Feeler gauge set
1)

100 ... 84

150

150

151

151

152

153

154

155

When fitting a new dished washer pack, air gap min has t be increasaed by 0,05 mm,
since the thickness of the dished washer pack decreases after some operations.

Mounting instructions

4.1

Tightening torques

Table 4.1

The screws of Demag brake motors have to be tightened according to the tightening
torques indicated in table 4.1. These tightening torques are also valid for screws with
a higher strength.

Tightening torques for screws

For hexagon socket head cap screws acc. to DIN 912 as well as acc. to DIN 6912 for flange mounting IM B 14
Screw size
Tightening torque

M5

M6

M8

M 10

M 12

M 16

6,0-7,5 Nm

10,5-14 Nm

25-30 Nm

50-60 Nm

86-100 Nm

215-255 Nm

Screw size

M5

M6

M8

M 10

M 12

M 16

Tightening torque
the case of cast iron

7,5 Nm

14 Nm

30 Nm

65 Nmn

100 Nm

270 Nm

Tightening torque
the case of die-cast
aluminium

9 Nm

18 Nm

45 Nm

75 Nm

4.2

20

Mounting, dismantling of SB
slip-ring motors

When mounting or dismantling SB slip-ring motors the brush holder arms have to be
locked home by means of the latch-in device. The brush holder arms can be released
again by lifting the latch-in device. During this make sure that the brush holder arm
springs back slowly.

21431844.p65/0898

For self-locking screws Verbus-Ripp in case of foot mounting as well as in the case of flange mounting IM B 5

Mains connection

Check voltage and set terminals accordingly!

When leaving our works, the terminals of our motors are unconnected.
5.1

One-speed connection

5.3

Connection with two separate windings for two

speeds and one voltage

W2

U2

V2

W2

U2

V2

2U

2V

2W

2U

2V

2W

U1

V1

W1

U1

V1

W1

1U

1V

1W

1U

1V

1W

L1

L2

L3

L1

L2

L3

L1

L2

41492844.eps

D connection

Y connection
D - connection for
power supply of
132 V
230 V

Motor for
132/230 V
230/400 V
500 V
600 V
690 V

5.2

41492944.eps

L3

Y connection
Low speed

Y-connection for
power supply of
230 V
400 V
500 V
600 V
690 V

Dahlander connection
for 2 speeds of a 1 : 2 ratio

L1

L2

41493044.eps

5.4

L3

41493144.eps

Y connection
High speed

Connection with one winding for one speed

and two voltages of a 1 : 2 ratio

2U

2V

2W

2U

2V

2W

U2

V2

W2

U2
U5

V2
V5

W2
W5

1U

1V

1W

1U

1V

1W

U5
U1

V5
V1

W5
W1

U1

V1

W1

L1

L2

L1

L2

L3

L1

L2

L1

L3

L2

L3

41493344.eps

41493044.eps

L3
41493444.eps

41493244.eps

D connection
Low speed

YY connection
High speed

YY connection
Low voltage

Y connection
High voltage

Dahlander connected (single-winding) motors are

designed for one line voltage only.

Rotor connection in the case of slip-ring motors

6.1

Two-pole rotor
for 6-pole SB 100 140 motors

M
21431844.p65/0898

6.2

Three-phase rotor
for 2 and 4-pole motors
for pole-changing motors (only high speed)
for 6-pole SB 160 225 motors

41493544.eps

41493644.eps

Connection to the starter or rotor controller resp.

L
41493744.eps

L
41493844.eps

Connection to the starter or rotor controller resp.

21

1 Page(s) Page 1

EC declaration of conformity
Demag AC brake motor
D-58286 Wetter

Ident. no.

in accordance with EC directives 89/336/EEC, Annex I,

and 73/23/EEC, Annex III

205 541 44
Issue 0697

EN

Hereby we,

Mannesmann Dematic AG
Antriebstechnik,
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 conformity 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 of

vibration severity

EN 60034-18-1

Functional assessment of insulation systems

EN 60529

Types of enclosure (IP Code)

Wetter, 11 June 1997

22

# = Modifications compared
to previous issue
Subject to alteration

i.V. Ropelius

ppa. Peters

Technik und Entwicklung

Vertrieb

Motoren

Antriebstechnik

7550 Normung

Class. no.

715 IS 911

Reproduction in whole or in part only with prior consent of Mannesmann Dematic AG, D-58286 Wetter

21431844.p65/0898

Place and date of issue

D-58286 Wetter

1 page(s) Page 1

EC manufacturers declaration
Demag brake motors

Ident. no.

in accordance with EC directive 89/392/EEC, Annex IIB

Issue 0797

204 911 44
EN

Hereby we,

Mannesmann Dematic AG
Antriebstechnik,
declare that the product

Demag brake motor

series

KL, SB
of serial design is intended to be incorporated into machinery and that the machinery
must not be put into service until the machinery into which this product is to be incorporated has been declared in conformity with the provisions of the following relevant
regulations:
EC Machinery Directive
amended by
EC EMC Directive
amended by

89/392/EEC
91/368/EEC
89/336/EEC
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 of

vibration severity

EN 60034-18-1

Functional assessment of insulation systems

EN 60529

Types of enclosure (IP Code)

Wetter, 23 July 1997

21431844.p65/0898

Place and date of issue

# = Modifications compared
to previous issue
Subject to alteration

i.V. Ropelius

ppa. Peters

Technik und Entwicklung

Vertrieb

Motoren

Antriebstechnik

7550 Normung

Class. no.

715 IS 910

Reproduction in whole or in part only with prior consent of Mannesmann Dematic AG, D-58286 Wetter

23

24

Subject to alteration

21431844.p65/0898
Printed
in Germany MBR/1298/6T

Reproduction in whole or in part only with prior consent of Mannesmann Dematic AG, D-58286 Wetter