Operating instructions

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

41239944.eps
21431844.p65/0898

0898 EN 214 318 44 720 IS 911 1

 Manufacturer Mannesmann Dematic AG
P.O. Box 67, D-58286 Wetter
Telephone (+49 2335) 92-0, Telefax (+49 2335) 927676
Internet http://www.dematic.com

Further documents 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

Contents 0 Foreword 4
0.1 Copyright 4
0.2 After-sales service 4
0.3 Guarantee 5
0.4 Limitations of liability 5
0.5 Definitions 6

1 Safety 7
1.1 Symbols 7
1.2 Intended use 7
1.3 Prohibited practises, improper use 7
1.4 Safety instructions 8
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 2 Receiving, transport and storage 9
2.1 Receiving 9
2.2 Transport 9
2.3 Storage 9

3 Brake motors
KBA, KBF, KBS, SBA, SBS ranges 10
3.1 General information on Demag brake motors 11
3.2 Inspection 11
3.2.1 Mechanical 11
3.2.2 Electrical 11
3.3 Mounting 12
3.3.1 Checking the state 12
3.3.2 Checking the site of installation 12
3.3.3 Alignment 12
3.3.4 Type of mounting 12
3.3.5 Oil-tight type 12
3.3.6 Outdoor mounting 12
3.3.7 Conversion of flange mounting into foot mounting 12
3.4 Transmission elements 13
3.4.1 Coupling, toothed wheel, belt, pulley 13
3.4.2 Protection against rust 13
3.4.3 Balancing 13
3.4.4 Fitting device 13
3.5 Connection 14
3.5.1 Performance of connection work 14
3.5.2 Switchgear 14
3.5.3 Protective measures 14
3.5.4 Trial run 14
3.6 Maintenance 15
3.6.1 Bearings 15
3.6.2 Slip-rings and brushes 15
3.6.3 Brake 16
3.7 Brake adjustment 16
3.8 Exchange of brake ring 17
3.9 Exchange of brake spring 17
3.10 Moving terminal box 18
3.10.1 KB 71 – 140 squirrel-cage motors 18
3.10.2 SB 100 – 140 slip-ring motors 18
3.10.3 KB 160 – 225 squirrel-cage motors, SB 160 – 225 slip-ring motors 18
3.11 Adjusting the air gap 19

4 Mounting instructions 20
4.1 Tightening torques 20
4.2 Mounting, dismantling of SB slip-ring motors 20

5 Mains connection 21
5.1 One-speed connection 21
5.2 Dahlander connection for 2 speeds of a 1:2 ratio 21
5.3 Connection with 2 separate windings for 2 speeds and one voltage 21
5.4 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 21
6.2 Two-phase rotor 21

EC conformity declaration 22
EC manufacturer’s declaration 23
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 0 Foreword

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 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 compensa-
tory damages. All industrial rights reserved.

0.2 After-sales service For technical information on Mannesmann Dematic products and their systematic
application, please refer to one of our after-sales service stations, the relevant repre-
sentative or to our main office in Wetter.

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 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 oper-
ating 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 descrip-
tions 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.
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 rea-
son 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 draw-
ings and illustrations are not to scale.
Only documentation belonging to the actual order is valid.
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 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 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 relevant
standards, 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 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, 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 technical
training and experience, have sufficient knowledge of the product and are familiar
with 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 operating
condition of KB., SB. motors.

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 1 Safety

1.1 Symbols The following symbols and recommendations indicate potential safety hazards or
causes of damage or provide useful information.

Hazard warning
This symbol appears in the operating instructions next to all instructions relating to
safety at work wherever a potential hazard to life and limb exists if the instructions are
not complied with.
Follow these instructions at all times and be particularly careful and cautious.
Pass on safety instructions to all persons entrusted with working on motors including
the 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. 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 discon-
nected.

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 appli-
cations. Compliance with the permitted operating conditions must be ensured for
operation of these drives (e.g. enclosure type, ambient temperature, installation
height).

1.3 Prohibited practises, Under certain conditions, operation of standard motors is prohibited as this could
result in malfunctions, faults in the equipment or hazard to life and limb, e.g.:
improper use
• Acidic, corrosive air as coolant.
• Operation outside the permitted temperature range.
• Operation beyond the normal air pressure. Otherwise, power adjustments are 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 other
than that for which they have been designed.
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 1.4 Safety instructions
Putting motors into operation
Additional safety instructions
8
The relevant national accident prevention regulations and the general safety condi-
tions must always be observed when our products are operated in order to avoid
accidents and damage to machinery. If the safety instructions given in these operat-
ing instructions are not observed in any way, personal injury or even death can result.
Dangerous voltage!
Motors are connected to a mains power supply. Any contact with live parts can lead
to very serious injury or even death.
Do this only
• if you have read the operating instructions and the owner has instructed you in all
details,
• if the operating instructions are available for reference at the place of operation,
• if you are qualified personnel (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.
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 2 Receiving, transport and storage

2.1 Receiving 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 in
transit. 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.

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 other-
wise 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 Fragile Keep dry Protect from heat

Top-heavy No hooks Attach sling here Centre of gravity

41283944 - 41284644.eps

Handle motors with utmost care to avoid damage caused by careless loading and
unloading, for example.

2.3 Storage Motors must be stored as follows:

• in dry places with low temperature fluctuations
• in the same position as for operation
• protected against dust and moisture
• on a wooden support
• free from vibration (no impacts)
Drives must not be stacked on top of each other.

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

teed for a period of 6 months. The guarantee period begins on the day the unit is
delivered.
Contact Mannesmann Dematic in Wetter, Germany, if geared motors are to be stored
for periods of longer than 6 months.
Important! Motors may otherwise be damaged.
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 3 Brake motors
KBA, KBF, KBS, SBA, SBS
ranges

Fig. 1

41415444.eps

Fig. 2 Execution
with conical brake disc with flat brake disc

1 2 3 5 7 8 9 10 11 12 14 16 17
4 6 13 15

41259744.eps

Demag brake motor with squirrel-cage rotor

KBA, KBF ranges
1 Shaft 9 Motor end cap, brake side 16 Flat brake disc, (shown: heavy flat brake
2 Motor end cap, drive side 10 Brake disc, also fan (shown: light conical disc)
21431844.p65/0898

3 Spring ring brake disc) 17 Flat brake ring

4 Thrust ring 11 Conical brake ring
5 Brake spring 12 Brake cap
6 Reduction rings 13 Tensioning nut
7 Stator 14 Tensioning screws
8 Rotor 15 Retaining ring
10
 3.1 General information on 1 The Demag brake motor is the combination of an electric motor and a spring-
Demag brake motors
loaded 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 Standard brake motor with squirrel-cage rotor
KBF Brake motor with squirrel-cage rotor designed as travel motor
KBS Torque motor with squirrel-cage rotor
SBA Standard brake motor with slip-ring rotor
SBS 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 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.

4 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).

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 shocks
during braking.

6 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.

7 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.

8 For the details concerning the additional equipment, as for example HBGL man-
ual 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 com-
pany, if the packing is in bad condition.
The shaft cannot be turned as rotor is braked during standstill.

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.
21431844.p65/0898

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
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 mounting
into foot mounting
12
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°C
Site 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 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.
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.
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 pro-
vided 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.
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 in
IM V 1 – with a protective roof. If required protective roofs for mounting IM V 1 can
be supplied.
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.
Screw on motor feet and machine them according to the feet height
(tolerance - 0,5 mm).
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 3.4 Transmission elements
3.4.1 Coupling, toothed wheel, belt, Coupling: Only use flexible couplings allowing easy axial movement be-
pulley tween 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 correspond-
ingly.

3.4.4 Fitting device When fitting or removing pinions, couplings and pulleys with appropriate device al-
ways 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 transmis-
sion elements.
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 3.5 Connection
3.5.1 Performance of connection Connections should be carried out by qualified personnel (VDE 0105) according to
work 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 termi-
nals 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 con-
ductors.

No special connections are necessary for the brake.

Threading of stud terminals in terminal box:

Motor size Stud
71, 80, 90 M4
100, 112, 125 M5
140, 160 M6
180, 200, 225 M8

3.5.2 Switchgear 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 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 inef-
fective.

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).
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.
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 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 Klüber 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 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 not
damaged.
Table 3.6.1 Quality of the anti-friction bearing greases
Ambient temperature Anti-friction bearing grease Operating temperature
°C type °C

Anti-friction bearing
-20 to +40 DIN 51502 -20 to +140
grease K3N-20
Anti-friction bearing
-20 to +80 DIN 51502 -20 to +160
grease K3P-20
Anti-friction bearing
-40 to +80 DIN 51502 -40 to +160
grease K3P-40
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.
• Newly fitted brushes should be ground in with superfinishing carborundum cloth.
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 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 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.

Table 3.6.3 Axial displacement of the shaft

Size Types
KBA, KBF, KBS, SBA, SBS
Displacement l v
l v min l v max
mm mm
71, 80, 90 1,5 3,0
100, 112 1,8 3,5
125, 140 2,0 4,0
160, 180, 200, 225 2,3 4,5

3.7 Brake When working on the brake, loads must be prevented from imparting a torque
to the shaft.
adjustment
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.

l v − l vmin
Number of turns to the left =
h

lv measured rotor displacement according to 1)

l v 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

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 than
l v min indicated in table 3.6.3.
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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
 3.8 Exchange of When working on the brake, loads must be prevented from imparting a torque
to the shaft.
brake ring
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 en-
tire 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 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 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 start-
ing and stopping motor repeatedly.

3.9 Exchange of 1) Take off drive end stator cap (2).

brake spring 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!
7) Refit drive end stator cap (2).
21431844.p65/0898

17
 3.10 Moving terminal box
3.10.1 KB 71 – 140 squirrel-cage
motors
3.10.2 SB 100 – 140 slip-ring motors
3.10.3 KB 160 – 225 squirrel-cage
motors
SB 160 – 225 slip-ring motors
18
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 termi-
nal box.
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.
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 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
 3.11 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 toler-
ances 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, tak-
ing 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 com-
pensation 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 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 to
the component parts list.
21431844.p65/0898

19
 Table 3.11
Correct air gap values and selection of feeler gauges

M ot or Size 71 80 90 100 112 125 140 160 180 200 225

Type Air gap d
KBA, KBS δ min 1) mm 0,25 0,25 0,30 0,30 0,35 0,35 0,40 0,45 0,50 0,50 0,55
SBA, SBS δ max mm 0,30 0,30 0,35 0,35 0,45 0,45 0,50 0,55 0,60 0,60 0,65
KBF δ min 1) mm 0,30 0,30 0,40 0,40 0,45 0,45 0,50 - - - -
δ max mm 0,35 0,35 0,50 0,50 0,55 0,55 0,60 - - - -
Feeler gauge
Size
0,25x3x250 X X
0,30x3x250 X X X X

0,35x3x300 X X X X X

0,40x3x300 X X X X X
0,45x3x300 X X X

0,50x3x300 X X X
0,55x3x300 X X X
0,35x5x300 X
0,40x5x300 X X
0,45x5x300 X X X

0,50x5x300 X X X X X X
0,55x5x350 X X X X X X
0,60x5x350 X X X X X X
0,65x5x350 X X X X
0,70x5x350 X X X

Feeler gauge set 100 ... 84 150 150 151 151 152 153 154 155 156 156 156

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

4 Mounting instructions
4.1 Tightening torques 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
Table 4.1 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 M5 M6 M8 M 10 M 12 M 16

Tightening torque 6,0-7,5 Nm 10,5-14 Nm 25-30 Nm 50-60 Nm 86-100 Nm 215-255 Nm

For self-locking screws Verbus-Ripp in case of foot mounting as well as in the case of flange mounting IM B 5
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 Mounting, dismantling of SB When mounting or dismantling SB slip-ring motors the brush holder arms have to be
slip-ring motors 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
21431844.p65/0898

springs back slowly.

20
 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 L3 L1 L2 L3
41492844.eps 41492944.eps 41493044.eps 41493144.eps

D connection Y connection Y connection Y connection

Motor for D - connection for Y-connection for
Low speed High speed
power supply of power supply of
132/230 V 132 V 230 V
230/400 V 230 V 400 V
500 V 500 V
600 V 600 V
690 V 690 V

5.2 Dahlander connection 5.4 Connection with one winding for one speed
for 2 speeds of a 1 : 2 ratio and two voltages of a 1 : 2 ratio

2U 2V 2W 2U 2V 2W U2 V2 W2 U2 V2 W2
U5 V5 W5

U5 V5 W5
1U 1V 1W 1U 1V 1W U1 V1 W1 U1 V1 W1

L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3
41493044.eps 41493344.eps 41493444.eps

41493244.eps

D connection YY connection YY connection Y connection

Low speed High speed Low voltage High voltage
Dahlander connected (single-winding) motors are
designed for one line voltage only.

6 Rotor connection in the case of slip-ring motors

6.1 Three-phase rotor 6.2 Two-pole rotor
for 2 and 4-pole motors for 6-pole SB 100 – 140 motors
for pole-changing motors (only high speed)
for 6-pole SB 160 – 225 motors

K K

L Q

M K L M L K Q L
21431844.p65/0898

41493544.eps 41493644.eps 41493744.eps 41493844.eps

Connection to the starter or rotor controller resp. Connection to the starter or rotor controller resp.
21
 1 Page(s) Page 1
EC – declaration of conformity
Ident. no.
Demag AC brake motor
in accordance with EC directives 89/336/EEC, Annex I,
205 541 44
D-58286 Wetter and 73/23/EEC, Annex III 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 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 of
vibration 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

i.V. Ropelius ppa. Peters

Technik und Entwicklung Vertrieb
Motoren Antriebstechnik
21431844.p65/0898

# = Modifications compared Class. no.

7550 Normung
to previous issue 715 IS 911
22
Subject to alteration Reproduction in whole or in part only with prior consent of Mannesmann Dematic AG, D-58286 Wetter
 1 page(s) Page 1
EC manufacturer’s declaration Ident. no.
Demag brake motors 204 911 44
D-58286 Wetter in accordance with EC directive 89/392/EEC, Annex IIB Issue 0797 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 incor-
porated has been declared in conformity with the provisions of the following relevant
regulations:

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 of
vibration 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

i.V. Ropelius ppa. Peters

Technik und Entwicklung Vertrieb
Motoren Antriebstechnik
21431844.p65/0898

# = Modifications compared Class. no.

7550 Normung
to previous issue 715 IS 910
23
Subject to alteration Reproduction in whole or in part only with prior consent of Mannesmann Dematic AG, D-58286 Wetter
 Reproduction in whole or in part only with prior consent of Mannesmann Dematic AG, D-58286 Wetter Subject to alteration
in Germany MBR/1298/6T
21431844.p65/0898
Printed

24