5.2.1 Brake power consumption 5.2.2 Electric connection, brake actuation times Selection criteria ZB motor standard connection diagrams to EN standard 5.4.1 ZBA/ZBE/ZBP standard motors, fitted with a brake 5.4.2 ZBF travel motors Connection diagram selection 5.5.1 Line operation 5.5.2 Inverter operation...
Page 4
Foreword You have purchased a Demag product. This equipment was manufactured in accordance with state-of-the-art engineering principles. These assembly instructions are designed to provide the user with appropriate instructions for safe and correct work and to facilitate maintenance. Every individual given the task of transporting, installing, commissioning,...
Page 5
We expressly point out that only genuine Demag spare parts and accessories approved by us may be used. Accordingly, this also applies to other manufacturers’...
Page 6
Safety 2.1 Symbols The following symbols and instructions warn against possible injuries or damage and are intended to assist you in your work. DANGER. This symbol indicates an immediate hazard which can result in serious injury or death. – Follow these instructions at all times and be particularly careful and cautious. WARNING.
Page 7
Safety devices must not be rendered inoperative. Only genuine Demag spare parts and accessories may be used. Observe prescribed deadlines or those specified in the assembly instructions for routine...
Page 9
The range of Demag cylindrical-rotor motors includes ZBA, ZBE, ZBP and ZBF motor types. The ZBA motor range consists of motor frame sizes 63 to 225 with 2, 4, 6 and 8 poles. ZBE motors have 4 poles, the motor range consists of frame sizes 63 to 225 in efficiency class IE2.
Page 10
4.1.2 Rating plates ZB. 63 A to ZB. 71 B motor rating plate The rating plate is arranged to the left or right of the terminal box on the motor end cap, e.g. Demag Cranes & Components GmbH Made in Germany 43601944.eps 43601945.eps...
Page 11
4.1.3 Motor enclosures ZB motors are supplied with IP 54 as standard. For brake sizes B003 - B680, IP 54 dust protection only applies for non-magnetic and non-magnetisable particles in this case. All motors are available with IP 55 and IP 65 enclosure, on request, which then also provides protection against magnetic or megnetizable particles.
Page 12
4.2 ZB. motor brake Demag B003 and B680 disc brakes are double-surface spring-actuated brakes featuring electro-magnetic brake release. The brake fitted under the fan cover can be controlled independently of the motor and causes no axial movement of the rotor shaft or forces on the bearings.
If required, the motor must be fitted with varistors. Brakes up to size B050 for ZBA/ZBE/ZBP motors and B140 for ZBF motors can also be supplied with 24 V DC from the installation control system. GF and GP brake rectifiers can be used parallel to the motor winding for pole- changing motors.
5.1.2 GP brake rectifiers (normal GP brake rectifiers can be used parallel to the motor winding for pole-changing excitation for pole-changing motors that have separate windings. They are used up to brake size B050 for ZBA motors) motors and B140 for ZBF motors.
5.1.3 GS brake rectifiers (high- GS brake rectifiers include a reversible rectifier and are used for ZBA, ZBE and speed excitation) ZBP motors with brakes as of size B140 as standard. In this case, the module must be supplied via 3 phases at terminals 5, 6 and 7. (Overexcitation factor of 2,5).
5.1.5 GU brake rectifiers (normal GU brake rectifiers can be used as an option for brakes with a separate AC power excitation) supply up to brake size B050. They are fitted in the brake motor terminal box as standard, but can also be alternatively used in a switchgear cabinet.
Page 17
3) 2 supply lines - overexcitation factor of 2 3 supply lines - overexcitation factor of 2,5 required for ZBA, ZBE and ZBP motors from brake size B140 4) Standard - Rated current of motor is equal to or smaller than the higher value of the SE current relay specified under “control current range” (single-phase motor current).
5.2 Brake selection table Assigned standard modules Standard brake torque ZBA/ZBE/ZBP ZBA/ZBE/ZBP Single-speed or Brake Supply voltage Note Single-speed Pole-changing pole-changing V AC B003 42 - 500 GE [3 A] GE [3 A] + SE ≤ 2,5 Nm ≤ 2,5 Nm...
Brake sizes B140 to B680 are generally controlled using a GS rectifier on ZBA, ZBE and ZBP motors. Brake application times are highly dependent on the way in which the brake is connected.
Page 20
• Connection in the DC circuit: 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. The rectifiers are protected against overvoltage at the switching contact by varistors.
5.3 Selection criteria The following criteria must be considered when selecting the connection diagram: • Motor to be operated with – one line voltage (e.g. 400 V, 50 Hz) or – two line voltages (e.g. ∆/Y 230/400 V 50 Hz or YY/Y 240/480 V 60 Hz) •...
5.5 Connection diagram selection 5.5.1 Line operation Select connection diagram for line operation 2 windings (Y/Y) up Table 1 to size 132, voltage > 500 V Special Table 2 connection diagram Common power B003 to B680 DC brake Table 3 1 line voltage? supply to motor and brake?
Page 24
Tables 1 – 2 Special connection diagrams Motor with 2 windings (Y/Y) up to size 132, line voltage > 500 V Supply Switch-off Brake size Control modules in terminal box none ≤ B050 ≤ B140 038 420 84 – – –...
Page 25
Y / Y ∆ / Y Switch-off Switch- Brake size for Control module in the terminal box method element ZBA / ZBP In DC Contact ≤ B050 ≤ B140 037 875 84 037 892 84 410 050 84 037 872 84 –...
Page 26
YY / Y (not suitable for inverter operation) Switch-off Switching Brake size for Control module in the terminal box method element ZBA / ZBP In DC circuit Contact ≤ B050 ≤ B140 037 857 84 037 883 84 410 050 84...
Single speed ∆ / Y YY / Y Switch-off method Switching Brake size for Control module in the terminal box element ZBA / ZBE In DC circuit Contact ≤ B050 ≤ B140 037 875 84 037 892 84 410 050 84...
5.6 Connection diagrams Dual voltage motor (1:√3) A: Common power supply to motor and brake Y high voltage ∆ low voltage The brake coil is 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 ∆...
Page 29
A: Common power supply to motor and brake Dual voltage motor (1:√3) Y high voltage ∆ low voltage The brake coil is 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 ∆...
Page 30
Motor for one line voltage, pole-changing, separate windings Separate power supply to brake * = Supply to high-speed winding via external switch-over. 1U, 1V, 1W for low speed 2U, 2V, 2W for high speed Switch-off in the DC circuit dependent on motor current Not suitable for inverter operation.
Page 31
Dual voltage motor 1:2 A: Common power supply to motor and brake Brake coil is rated for the low voltage. YY low voltage Y high voltage Not suitable for inverter operation. B: Separate power supply to brake For inverter operation, connect the motor with YY or Y connection according to the inverter settings.
Page 32
Motor for one line voltage The brake coil is rated for the phase voltage. A: Common power supply to motor and brake B: Separate power supply to brake Switch-off in the DC circuit dependent on motor current Not suitable for inverter operation. WH GY 03786584.eps Motor supplied with:...
Page 33
Motor for one line voltage, pole-changing, separate windings 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 Switch-off in the DC circuit dependent on motor current Not suitable for inverter operation.
Page 34
Motor for one line voltage or dual voltage high voltage motor (1:√3) ∆ low voltage Voltage-dependent switch-off in the DC circuit Separate power supply to brake For inverter operation, connect the motor with Y or ∆ VE+ GE1 BD1 connection according to the inverter settings. Δ...
Page 35
Motor for one line voltage Switch-off in the DC circuit A: Common power supply to motor and brake dependent on motor current B: Separate power supply to brake Not suitable for inverter operation. WH GY V1 U1 2L2 2L1 03788284.eps Motor supplied with: •...
Page 36
Motor for one line voltage The brake coil is rated for the phase voltage. A: Common power supply to motor and brake B: Separate power supply to brake Switch-off in the DC circuit dependent on motor current Not suitable for inverter operation. WH GY U2 U1 2L2 2L1...
Page 37
Motor for one line voltage, pole-changing, separate windings Separate power supply to brake * = Supply to high-speed winding via external switch-over. 1U, 1V, 1W for low speed 2U, 2V, 2W for high speed Switch-off in the DC circuit dependent on motor current 1L2* 1L3* Not suitable for inverter operation.
Page 38
Dual voltage motor (1:2) A: Common power supply to motor and brake The brake coil is rated for the low voltage. YY low voltage Y high voltage Not suitable for inverter operation. B: Separate power supply to brake For inverter operation, connect the motor with YY or Y connection according to the inverter settings Switch-off in the DC circuit •...
Page 39
Motor for one line voltage A: Common power supply to motor and brake Not suitable for inverter operation. B: Separate power supply to brake For inverter operation, connect the motor with Y Δ or ∆ connection according to the inverter settings Switch-off in the DC circuit •...
Page 40
Motor for one line voltage Switch-off in the DC circuit dependent on motor current A: Common power supply to motor and brake B: Separate power supply to brake Not suitable for inverter operation. WH GY V1 U1 2L2 2L1 03789484.eps Motor supplied with: •...
Page 41
Motor for one line voltage or dual voltage high voltage motor (1:√3) ∆ low voltage Separate DC power supply to brake For inverter operation, connect the motor with Y or ∆ connection according to the inverter settings. Δ 03789784.eps Motor supplied with: •...
Page 42
Dual voltage motor (1:2) YY low voltage high voltage Separate DC power supply to brake For inverter operation, connect the motor with YY or Y connection according to the inverter settings. 03789984.eps Motor supplied with: • Motor winding connected with Y connection. •...
Page 43
Motor for one line voltage, pole-changing, separate windings Separate power supply to brake * = Supply to high-speed winding via external switch-over. 1U, 1V, 1W for low speed 2U, 2V, 2W for high speed Switch-off in the DC circuit 1L2* 1L3* dependent on motor current Not suitable for inverter operation.
Page 44
Dual voltage motor (1:2) A: Common power supply to motor and brake The brake coil is rated for the low voltage. YY low voltage Y high voltage Not suitable for inverter operation. B: Separate power supply to brake For inverter operation, connect the motor with YY or Y connection according to the inverter settings Switch-off in the DC circuit...
Page 45
Motor for one line voltage A: Common power supply to motor and brake Not suitable for inverter operation. B: Separate power supply to brake For inverter operation, connect the motor with Y Δ or ∆ connection according to the inverter settings Switch-off in the DC circuit •...
Page 46
Motor for one line voltage Switch-off in the DC circuit dependent on motor current A: Common power supply to motor and brake B: Separate power supply to brake Not suitable for inverter operation. WH GY 03800884.eps Motor supplied with: • Jumper parts to connect the motor winding with Y connection enclosed.
Page 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. B: Separate power supply to brake 1L2* 1L3*...
Page 48
Motor for one line voltage, pole-changing, separate windings Separate power supply to brake * = Supply to high-speed winding via external switch-over. 1U, 1V, 1W for low speed 2U, 2V, 2W for high speed VE+ GS1 BD1 Voltage-dependent switch- off in the DC circuit 1L2* 1L3* 1L1*...
Page 49
Motor for one line voltage or dual voltage motor (1:2) YY low voltage high voltage A: Common power supply to motor and brake. Brake coil only rated for the high voltage. Not suitable for inverter operation. B: Separate power supply to brake. For inverter operation, connect the motor with YY or Y connection according to the inverter settings.
Page 50
Motor for one line voltage, pole-changing, separate windings * = Supply to high-speed winding via external switch-over. 1U, 1V, 1W for low speed 2U, 2V, 2W for high speed Switch-off in the DC circuit dependent on motor current Not suitable for inverter operation. 1L2* 1L3* = Intermediate terminal 1W 1V...
Page 51
Motor for one line voltage, pole-changing, separate windings * = Supply to high-speed winding via external switch-over. 1U, 1V, 1W for low speed 2U, 2V, 2W for high speed Common power supply to motor and brake Not suitable for inverter operation. 1L1* 1L2* 1L3*...
Page 52
Motor for one line voltage, pole-changing, separate windings 2U, 2V, 2W for high speed Common power supply to motor and brake Only the high speed winding is used. Switch-off in the DC circuit dependent on motor current Not suitable for inverter operation. = Intermediate terminal WH GY WH GY...
Page 53
Motor for one line voltage, pole-changing, separate windings 2U, 2V, 2W for high speed Common power supply to motor and brake Only the high speed winding is used. Switch-off in the DC circuit dependent on motor current Not suitable for inverter operation. = Intermediate terminal 03842484.eps Motor supplied with:...
Page 54
Motor for one line voltage, pole-changing, separate windings * = Supply to high-speed winding via external Separate DC power supply to brake, maximum voltage 500 V AC switch-over. 1U, 1V, 1W for low speed 2U, 2V, 2W for high speed Switch-off in the DC circuit •...
Page 55
Motor for one line voltage, pole-changing, separate windings * = Supply to high-speed winding via external Separate DC power supply to brake switch-over. 1U, 1V, 1W for low speed 2U, 2V, 2W for high speed 1L1* 1L2* 1L3* 03842884.eps Motor supplied with: •...
Page 56
Motor for one line voltage, pole-changing, separate windings * = Supply to high-speed winding via external Separate DC power supply to brake, maximum voltage 500 V AC switch-over. 1U, 1V, 1W for low speed 2U, 2V, 2W for high speed Voltage-dependent switch- off in the DC circuit VE+ GE1 BD1...
Page 57
Motor for one line voltage, pole-changing, separate windings * = Supply to high-speed winding via external Separate DC power supply to brake, maximum voltage 500 V AC switch-over. 1U, 1V, 1W for low speed 2U, 2V, 2W for high speed Voltage-dependent switch- off in the DC circuit VE+ GS1 BD1...
Page 58
Motor for one line voltage, pole-changing, separate windings * = Supply to high-speed winding via external switch-over. Separate DC power supply to brake, maximum voltage 500 V AC 1U, 1V, 1W for low speed 2U, 2V, 2W for high speed Voltage-dependent switch- off in the DC circuit VE+ GS1 BD1...
Page 59
Motor for one line voltage A: Common power supply to motor and brake Not suitable for inverter operation. B: Separate power supply to brake For inverter operation, connect the motor with Y or ∆ connection according to the inverter settings. Δ...
Page 60
Dual voltage motor 1:2 A: Common power supply to motor and brake Brake coil is rated for the low voltage. YY low voltage Y high voltage Not suitable for inverter operation. B: Separate power supply to brake For inverter operation, connect the motor with YY or Y connection according to the inverter settings.
5.7 Connecting Depending on the motor features, the connections for temperature monitoring and/ or brake monitoring are brought out on Euro terminals in the terminal box. temperature and brake The following connection designations are used: monitoring devices • PTC thermistor –...
Transport, packing, storage 6.1 Safety warnings WARNING. Suspended load. Falling parts. Risk of injury from falling parts Secure components when they are transported. Do not step under suspended loads. CAUTION. Danger caused by inappropriate transport Inappropriate transport may result in damage to the motor. Lift loads only at the marked lifting points.
Assembly 7.1 Checking the Before installing the equipment, check to ensure it has not suffered any damage while in transit or in storage, such as corrosion, leaks, deformation or breakage. condition of the motor IMPORTANT. Do not clean motors with compressed air. 7.2 Checking the Standard motors are suitable for operation in normal industrial conditions.
7.6 Changing the terminal The position of the terminal box on ZB motors must only be changed at a later date by trained specialist personnel. box position at a later Follow the steps described below. date Max. 3 mm 41656744.eps 41665845.eps Undo the four retaining bolts between the stator Pull the stator housing by no more than 3 mm...
7.7 Instructions for connecting the motor DANGER. Live components Danger to life and limb. Electric energy can cause very severe injuries. Danger of death caused by electric current if the insulation or individual components are damaged. • Switch the machine off and secure it against restoration of the power supply before any maintenance, cleaning or repair work is carried out.
Putting the unit into service 8.1 Safety warnings DANGER. Electric current. Electric energy can cause very severe injuries. • Work on electric equipment may only be carried out by specialists or by trained personnel. • Switch the unit off and secure it against restoration of the power supply before any maintenance, cleaning or repair work is carried out.
CAUTION. Burns Higher temperatures (90 °C) must be expected in the area of the stator housing over longer periods of operation. When working on the parts, ensure • that you avoid any contact with parts of the housing in this area to prevent burns.
Maintenance 9.1 Safety instructions DANGER. Electric current. Electric energy can cause very severe injuries. • Work on electric equipment may only be carried out by specialists or by trained personnel. • Switch the unit off and secure it against restoration of the power supply before any maintenance, cleaning or repair work is carried out.
CAUTION. Burns Higher temperatures (90 °C) must be expected in the area of the stator housing over longer periods of operation. When working on the parts, ensure • that you avoid any contact with parts of the housing in this area to prevent burns.
Brake size B003 B007 B020 B050 B140 B280 B680 Motor ZBA / ZBE / ZBP Brake air gap s 0,35 1 min. Brake air gap s 0,65 0,65 0,65 1 max. Motor Brake air gap s 0,35 –...
Overhaul sets and wearing part sets are available for general overhauls. ZBA/ZBE/ZBP motors Overhaul set Wearing part Brake size ZBA / ZBE ZBA / ZBE / ZBP ZBA / ZBE / ZBP ZBA / ZBE / ZBP ZBA / ZBE / ZBP ZBA / ZBE ZBA / ZBE...
Page 72
Brake disc (3) Friction plate (14) End cap (6) 42029146.eps Brake air gap s = 0,30 mm - s = 1,0 mm (ZBA, ZBE) 1min 1max Brake air gap s = 0,30 mm - s = 1,2 mm (ZBF) 1min...
Page 73
Checking and adjusting the brake air gap B007-B680 brake Brake size B007 B020 B050 B140 B280 B680 Motor ZBA / ZBE / ZBP Brake air gap s 0,35 1 min. Brake air gap s 0,65 0,65 0,65 1 max. Motor...
9.4.3 Replacing the brake disc IMPORTANT. Damaged brakes may only be repaired by a workshop that is authorised by the manufacturer. Please also refer to our notes in section 9.5. B003 brake: disassembly/assembly Remove terminal box cover (11). Undo hexagon nut (10) and pull off washers (15), magnet assembly (9) and, if necessary, covering tape (12).
Page 75
O-ring (14) 42288144.eps Remove stop plate (1), armature plate (2), distance springs (5), brake disc (3) and O-ring (14) (O-ring (14) only for ZBA/ZBE/ZBP motors). Check collared pins (4) and braking surfaces for wear. IMPORTANT. Replace worn or damaged parts.
Page 76
Disassembly/assembly Collared pins/end cap (6) – if required Remove end cap (6). Unscrew the three defective collared pins (4). Fit new collared pins (4). Fit new end cap (6). B007-B050 brakes for ZBF motors NOTE. Retaining plate (7) is only fitted on units with IP55 enclosure.
Page 77
Also to be considered when installing B007 - B680 brakes on ZBA, ZBE and ZBP motors: 1) Fit O-ring (14) onto the carrier. 1) Fit O-ring (14) 2) Fit brake disc (3). O-ring retaining groove 3) Push brake disc (3) into position.
9.4.4 Brake spring arrangement and associated brake torques B003 brakes on ZBA, ZBE and ZBF motors Push distance springs (5) onto stud screws (4). Place brake springs (8) into magnet assembly (9). Brake spring (8) Insert covering tape (12) into the groove of end cap (6), if required.
Page 79
Arrangement of brake springs for ZBA/ZBE/ZBP motors not fitted with a manual brake release unit Brake size B007 B020 B050 B140 B280 B680 Quantity of springs Brake torque MB in Nm For spring arrangement see item White Blue – –...
42506946.eps 9.4.5 Bolt tightening torques Tighten the bolts on Demag ZB. motors to the tightening torques given in the table below. This also applies when high-tensile bolts are used. Bolt tightening torques For hexagon socket bolts to DIN 912 and to DIN 6912 for IM B 14 fl ange mounting...
9.5 Options The following options are possible: • Sealing arrangement (covering tape) for IP55/IP65 for B003 – B680 brakes • Reduced noise level – Option for B007 - B020 brakes – Standard for B050 - B680 brakes • Manual brake release Manual brake release is only available for B007 - B680 brakes, not for B003 brakes.
B007 – B680 for ZBA, ZBE and ZBP motors if the brake is operated only rarely (e.g. emergency stop for inverter operation). For higher thermal loading, increased wear of the lining and its counter-surface must be expected.
10 Troubleshooting Item Problem Possible cause Solution 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”...
Directive. To simplify the compilation of a conformity declaration according to the Machinery Directive by the manufacturer who uses these motors, Demag Cranes & Components GmbH declares conformity of the motors as the supplier according to DIN EN ISO/IEC 17050-1.
EU Directive 2014/35/EU, Annex IV Issue Page 0119 1/ 1 Hereby we, Demag Cranes & Components GmbH Forststrasse 16, 40597 Düsseldorf, Germany declare that the products: Demag AC motor type: Z motor KB motor of serial design, with or without the relevant gearboxes,...
Page 88
DIN EN ISO/IEC 17050-1 Issue Page 0119 1/ 1 Hereby we, Demag Cranes & Components GmbH Forststrasse 16, 40597 Düsseldorf, Germany declare that the product Demag AC motor type: Z motor KB motor of serial design, with or without the relevant gearboxes,...
Page 89
Issue Page 0721 1/ 1 Schedule 8 Hereby we, Demag Cranes & Components GmbH Forststrasse 16, 40597 Düsseldorf, Germany declare that the products: Demag AC motor type: Z motor KB motor of serial design, with or without the relevant gearboxes, has been declared in conformity with the following statutory instrument: Electrical Equipment (Safety) Regulations 2016 No.
Page 92
PO Box 67 · 58286 Wetter (Germany) Phone +49 (0)2335 92-0 +49 (0)2335 92-7676 www.demagcranes.com Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, 58286 Wetter (Germany) Subject to change. Not liable for errors or omissions.
Need help?
Do you have a question about the ZBA and is the answer not in the manual?
Questions and answers