Ensamblaje Motor Z Demag

Assembly instructions
Z motor range
41807744.eps
100709 enEN 214 228 44 719 IS 919

Genuine assembly instructions
Manufacturer Demag Cranes & Components GmbH

Drives
P.O. Box 67, D-58286 Wetter
Telephone +49 (0 ) 2335 92-5555 · Telefax +49 (0) 2335 92-2406
E-mail: drives@demagcranes.com
www.demagcranes.com
Accompanying documents For geared motors, also refer to the gearbox assembly instructions.
General documents Part No.

DE EN FR ES
Brochures
Demag Drives brochure 208 732 44 208 734 44 208 735 44 208 736 44
Demag wheel range brochure 208 722 44 208 724 44 208 725 44 208 726 44
Catalogues / technical Data
Drive Designer Online www.demag-drivedesigner.com

Geared motors catalogue – DE / EN / FR 203 150 44 –
Geared motors catalogue – IT / EN / ES – 203 250 44 – 203 250 44
DRS wheel block system 203 350 44 203 352 44 203 353 44 203 354 44
Demag RAE/RNE wheel sets technical data 203 687 44 203 688 44 203 689 44 203 690 44
Geared travel motors catalogue – Volume 3 – Quick selection and gearbox limit torque – DE / EN / FR 203 013 44 –
Geared travel motors catalogue – Volume 3 – Quick selection and gearbox limit torque – IT / EN / ES – 203 014 44 – 203 014 44
Assembly instructions
D 11 – D 41 helical gearbox assembly instructions 214 719 44 214 720 44 214 721 44 214 722 44
D 50 – D 90 helical gearbox assembly instructions 214 150 44 214 151 44 214 152 44 214 153 44
W 10 – W 100 angular gearbox assembly instructions 214 057 44 214 058 44 214 059 44 214 060 44
A 10 – A 90 offset gearbox assembly instructions 214 205 44 214 206 44 214 207 44 214 208 44
Motor assembly instructions – Z motor range 214 227 44 214 228 44 214 229 44 214 230 44
KBA – KBF motor assembly instructions 214 317 44 214 318 44 214 319 44 214 320 44
Brake accessories for Z motor range, assembly instructions 214 040 44 214 041 44 214 042 44 214 043 44
Assembly instructions / Plug connection for KB and Z motor ranges 214 021 44 214 022 44 214 023 44 214 024 44
DRS 112 – 200 wheel block system assembly instructions 214 275 44 214 276 44 214 277 44 214 278 44
DRS 250 – 500 wheel block system assembly instructions 214 326 44 214 327 44 214 328 44 214 329 44
RAE/RNE wheel sets assembly and maintenance instructions 214 132 44 214 133 44 214 134 44 214 135 44
Z motor spare part lists
Frame sizes Z63 / 71 222 856 44 222 857 44 222 858 44 222 859 44
Frame sizes Z80 / 90 A 222 864 44 222 865 44 222 866 44 222 867 44
Frame sizes Z90 B / 100 222 876 44 222 877 44 222 878 44 222 879 44
Frame sizes Z112 A / 132 222 884 44 222 885 44 222 886 44 222 887 44
Frame sizes Z160 / 180 A 222 892 44 222 893 44 222 894 44 222 895 44
Frame sizes Z180 B / 200 222 896 44 222 897 44 222 898 44 222 899 44
Frame sizes Z225 222 900 44 222 901 44 222 902 44 222 903 44
Contents 0 Foreword 4
0.1 Copyright 4
0.2 After-sales service 4
0.3 Liability for defects 4
0.4 Limitations of liability 5
0.5 Definitions 5
1 Safety 6
1.1 Symbols 6
1.2 Intended use 6
1.3 Prohibited practises, improper use 6
1.4 Safety instructions 7
214228k1.indd/270508
2 General 8
2.1 Models and terminal box position 8
2.2 Motor enclosures 8
2.3 Storage 8
2
3 Product description 9
3.1 Motor 9
3.1.1 Motor type designation 9
3.1.2 Rating plates 10
3.2 ZB. motor brake 11
4 Installation 12
4.1 Checking the condition of the motor 12
4.2 Check the installation location 12
4.3 Installing the motor 12
4.4 Special instructions for installing the motor 12
4.5 Instructions for connecting the motor 12
5 Putting into operation 13

5.1 Requirements 13
5.2 Check when commissioning 13
5.3 Geared motors 13
6 Maintenance 14
6.1 Inspection before starting work and during operation 14
6.2 Maintenance schedule 14
6.3 B003 - B680 brakes 15
6.3.1 Removing and fitting the fan cover and fan 16
6.3.2 Checking and adjusting the air brake gap s 1 17
6.3.3 Replacing the brake disk 19
6.3.4 Brake spring arrangement and associated brake torques 23
6.3.5 Bolt tightening torques 27
6.4 Options 28
6.4.1 Sealing B003 - B680 brakes, IP55 28
6.4.2 Reduced noise level 29
6.4.3 Manual brake release unit 29
6.4.4 Micro-switch 29
6.4.5 Emergency-stop brake lining 29
7 Motor/brake connection diagrams 30

7.1 B003 to B680 brake control 30
7.1.1 GE brake rectifiers (normal excitation) 31
7.1.2 GP brake rectifiers (normal excitation for pole-changing motors) 31
7.1.3 GS brake rectifiers (high-speed excitation) 32
7.1.4 GF brake rectifiers (normal excitation) 32
7.1.5 GU brake rectifiers (normal excitation) 33
7.1.6 SE current relays (motor current-dependent high-speed trip relay) 33
7.1.7 VE voltage relays (voltage-dependent high-speed trip relay) 33
7.2 Brake operating times 35
7.2.1 Brake power consumption 36
7.2.2 Electrical connection, brake operation times 36
7.3 Selection criteria 38
7.4 Z motor standard connection diagrams to EN standards 38
7.4.1 ZNA standard motors, not fitted with a brake 38
7.4.2 ZBA standard motors, fitted with a brake 39
7.4.3 ZBF travel motors 39
7.5 Connection diagram selection 40
7.5.1 Line operation 40
7.5.2 Inverter operation 44
7.6 Connection diagrams 45
7.7 Connecting temperature and brake monitoring devices 80
8 Technical data 81
9 Troubleshooting 82
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EC conformity declaration 83
3
0 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 operator with appropriate
instructions for safe and correct operation and to facilitate maintenance.
Every individual given the task of transporting, installing, commissioning, operating,

maintaining and repairing our Z motors and their additional equipment must have
read and understood
• the assembly instructions
• the safety regulations
• the safety instructions in the individual chapters and sections.
The assembly 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 assembly instructions must be treated confidentially. They should only be
used by authorized personnel. They may only be entrusted or made available to
third parties with the prior written consent of Demag. All documents are protected
within the sense of copyright law.
No part of this documentation may be reproduced, utilized or transmitted without

specific prior consent. Infringements are an offence resulting in obligatory compen-
satory damages. All industrial rights reserved.
0.2 After-sales service For technical information on our products and their systematic application, please
refer to one of our after-sales service stations, the relevant representative or to our
main office in Wetter.
0.3 Liability for defects These assembly 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 assembly instructions.
Any liability claims for defects must be made by quoting the order number immedi-
ately on detecting the defect.Any liability claims for defects are void in the event of:
• inappropriate use,
• faulty devices or equipment connected or attached to the product which are not
part of our scope of supplies and services,
• use of non-genuine spare parts and accessories,
• refurbishment or modification of the product unless approved in writing by
Demag.
Wearing parts are not subject to liability for defects.
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4
0.4 Limitations of liability All technical information, data and instructions for operation contained in these
assembly 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 the motors which are the subject of these assembly
instructions. Therefore, no claims can be derived from the information, illustrations
and descriptions contained in these assembly instructions.
The descriptions and illustrations contained in this documentation do not neces-
sarily correspond to the scope of delivery or any subsequent spare part delivery,
either; the drawings and illustrations are not to scale. Only documentation belong-
ing to the actual order is valid.
We assume no liability for damage and malfunctions caused as a result of operating
errors, non-compliance with these assembly instructions or inappropriate repairs
and maintenance. 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‘ parts supplied by us. For
safety reasons, the fitting and use of spare parts or accessories which have not
been approved and unauthorized modification and conversion of the product are
not permitted and exempt Demag Cranes & Components from any liability for
damages resulting therefrom.
With the exclusion of any further claims, our liability for defects and liability obliga-
tions for any defects pertaining to the products supplied or faults in the documenta-
tion delivered or any negligence on our part are exclusively based on the stipula-
tions of the original contract. Any further claims, in particular any and all claims
for damages, are excluded with the exception of legal claims in accordance with
product liability legislation.
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 operate the product.
Specialist personnel
Specialist personnel are defined as persons assigned by the owner to carry out
specific tasks, such as installation, setting-up, maintenance and fault elimination.
• Qualified personnel
Qualified personnel 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 and prevent 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 in-
correct handling and who have been informed about the required protective
devices, protective measures, relevant regulations, codes of practice, accident
prevention regulations and operating conditions and who have proven their
qualifications.
• Experienced technician
Experienced technicians are defined as persons, who, owing to their technical
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training and experience, have sufficient knowledge of the product and are fa-
miliar with the relevant national industrial safety regulations, codes of practice,
accident prevention regulations, directives and generally accepted engineering
standards (e.g. EC Directives, German VDE and BGV regulations) enabling
them to judge the safe operating condition of Z.. motors.
5
1 Safety
1.1 Symbols These symbols are used to warn against potential safety hazards or causes of
damage or provide useful information.
Hazard warning
This symbol appears in the assembly 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 vigilant and cautious.
Pass on safety instructions to all persons entrusted with working on the motor
including the power supply.
In addition to the safety instructions, observe all general safety regulations at all
times.
Warning against dangerous electrical voltage

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

This symbol in the assembly instructions indicates all warnings which, if not com-
plied with, may result in damage to the motor.
1.2 Intended use These motors are intended for all travel, lifting and turning motions in industrial
applications. Compliance with the permitted operating conditions must be ensured
for operation of these drives (e.g. enclosure type, ambient temperature, installation
height).
1.3 Prohibited practises, Under certain conditions, operation of motors in the standard design is prohibited
as this could result in malfunctions, equipment failure or hazard to life and limb,
improper use e.g. in the case of:
• Acidic, corrosive air as coolant
• Operation outside the permissible temperature range
• Operation outside the normal air pressure range Otherwise, power adjustments
are necessary
• Operation under conditions of high humidity or splashwater
• Manipulation of electrical modules.
Safety devices must not be rendered inoperable or modified or used in any way
other than that for which they have been designed.
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6
1.4 Safety The relevant national accident prevention regulations and the general safety
conditions must always be observed when our products are operated in order to
instructions avoid accidents and damage to machinery. If the safety instructions given in these
assembly instructions are not observed in any way, personal injury or even death
can result.
Warning against dangerous electrical 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 assembly instructions and the owner has instructed you in
all details
• if the assembly instructions are available for reference at the place of operation,
• if you are qualified personnel,
• if you are not under the influence of drugs, alcohol or medication that can ad-
versely affect your ability to react,
• if the general accident prevention, operating and installation regulations (e.g.
DIN-VDE 0100/0113) have been observed.
Additional safety instructions Only carry out maintenance and installation work
• if you are qualified specialist personnel,
• if the motors are at zero voltage,
• if no hazard exists (e.g. crushing hazard, slipping hazard, etc.),
• if the motors are secured against restoration of the power supply,
• if all cables and motor terminals are at zero potential (establish with a voltmeter),
• with insulated tools,
• using genuine spare parts.
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7
2 General
2.1 Models and terminal The available foot and flange-mounted motors correspond to the overview of
models. Demag motors are supplied with only one shaft end. The connection
box position dimensions largely correspond to IEC Publication 72-1. The foot motor largely
corresponds to DIN 42673, the flange motor corresponds to DIN 42677.
2.2 Motor enclosures ZN and ZB motors are supplied with IP 54 as standard. For brake sizes B004
- B680, IP 54 dust protection 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 megnetisable
particles.
Brief explanation of enclosures:
IP 54 Protection against harmful dust accumulation, protection against splashwater

from all directions.
IP 55 Protection against harmful dust accumulation, protection against hose-water

Detailed descriptions of these enclosures and test methods can be found in
EN 60034 part 5 (DIN VDE 0530, part 5).
IP 65 Complete protection against dust accumulation, protection against hose-water

Detailed descriptions of these enclosures and test methods can be found in
EN 60529.
Outdoor operation If a motor is operated under arduous conditions outdoors, e.g. unprotected instal-
lation in rain and wind or installation at great height, the standard IP 54 enclosure
may not be sufficient.
In these cases the motor must be provided with IP 55 enclosure or protected by
suitable measures, e.g. wind and rain deflector. For vertically mounted motors with
the shaft facing downwards, a canopy is available at an extra price.
2.3 Storage Motors must be stored as follows:

• in dry places with only minor temperature fluctuations
• in their service position
• protected against dust and moisture
• on a timber support
• free from vibration (no impacts).
Motors must not be stacked on top of each other.
Unless agreed otherwise, liability for defects is granted for the standard preservation
in accordance with our terms and conditions of delivery. The period begins on the
day the unit is delivered.
Contact Demag in Wetter, Germany, if the motors are to be stored for more than
6 months before they are put into operation.
Important: Motors may otherwise be damaged.

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8
3 Product description
3.1 Motor Demag type Z.. cylindrical rotor motors can be supplied with or without brake (ZB.
and ZN. motors). The ZBA and ZBN motor range includes sizes Z..63 to Z..225.
The output ratings of these 2, 4, 6 and 8-pole motors are graded according to
the IEC classification. The motor range includes pole-changing designs and ZBF
63 ... 132 motors with integrated fly wheels for particularly smooth load movement.
The housings of motor frame sizes Z..63 to Z..132 are of a high quality aluminium
alloy with an integrated terminal box base. The terminal box cover and fan cover
are made of plastic.
Motor frame sizes Z..160 to Z..225 have a grey cast iron housing with a fitted
terminal box.
All motors can also be supplied in flange and foot design with IEC shaft dimensions
and also fitted to Demag gearboxes.
3.1.1 Motor type designation
Brake size
Terminal box position
ZBA: B003, B007, B020, B050, B140, B280, B680
ZBF: B003, B007, B020, B050, B140 0, 1, 2, 3
Z B A 100 A 4 B050 B3 1
Number of poles Mounting code to DIN
2, 4, 6, 8, 8/2, 12/2, 12/4 EN60034-7, only needs to be
specified for solo motors
B3, B5, B6, B7, B8, B14, V1,
V3, V5, V6, V18, V19
Rating class
A, AL, B, C
Size
ZBA/ZNA: 63, 71, 80, 90, 100, 112, 132, 160, 180, 200, 225
ZBF: 63, 71, 80, 90, 100, 112, 132
Application code
A Motor for general applications F Motor for travel applications
Motor design
B Motor with brake (ZBA, ZBF)
N Motor without brake (ZNA)
Motor type
Z cylindrical rotor motor
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9
3.1.2 Rating plates
Rating plate for Z.. 63 A to Z.. 71 B motors with/without brake
The rating plate is arranged to the left or right of the terminal box on the motor end cap, e.g.
1 Demag Cranes & Components GmbH Made in Germany

EN 60034-1
2 Typ: ZBA 71 B 4 B007 3 ~ IP: 54 Iso : F IM B5-1
3 Mot.Nr .: 71740301 100 %ED 0,37 kW
4 10,0 kg FI: --- 50 Hz cos ϕ 0,60
5 1380 1/min c/h --- ˚C
6 230 V 2,50 A
400 V 1,40 A
7 Bremse: 5,1 Nm AC 400 V DC 180 V 0,14 A
8 ANR: 85674100 ASN: 00201 EFF.
41806344.eps
Rating plate for Z.. 80 A to Z.. 132 C motors with/without brake
The rating plate is arranged to the left or right of the terminal box base, e.g.
1 Demag Made in Germany

Cranes & Components GmbH EN 60034-1
10 Typ: ZBA 80 A 8 B007 3~ IP: 54
11 Mot.Nr.:71739107 Iso.: F 100 %ED
12 0,18 kW cosϕ : 0,57 50 Hz
5 670 1/min ---- c/h ---- ˚C
6
Δ 230 V 1,70 A
Y 400 V 0,95 A
7 Bremse: 5,1 Nm AC 400 V DC 180 V 0,14 A
9 IM B5 - 1 16,0 kg FI: ---
8 ANR: 85674300 ASN: 00401 EFF.
41806444.eps
Rating plate for Z.. 160 A to Z.. 225 B motors with/without brake
The rating plate is arranged to the left or right next to the terminal box on the stator, e.g.
1 Demag Cranes & Components GmbH EN 60034-1

2 Type: ZBA 160 B4 B280 3 ~ IP 54 Iso.: F IM B3-1
3 Mot.Nr: 12345678 100 %ED 15,0 kW
Made in Germany
4 183 kg Fl: 50 Hz cos ϕ : 0,84

5 1440 1/min c/h 40 ˚C
6 Δ 230 V 51,00 A
Y 400 V 29,0 A
7 Bremse: 185 Nm AC 400 V DC 180 V 0,45 A
8 ANR: 59021500 ASN:19301 EFF.
41965544.eps
1 Manufacturer, country of origin, regulation

2 Type designation, number of phases, enclosure, temperature class, model
3 Motor number, duty factor, power factor
4 Motor weight, inertia factor, frequency, power factor
5 Speed, switching frequency, ambient temperature > 40 °C
6 Connection, voltage, current
7 Brake: brake torque, supply voltage, coil voltage, coil current
8 Order number, entry number
214228k2.indd/100709
9 Model, motor weight, inertia factor

10 Type designation, number of phases, enclosure
11 Motor number, temperature class, duty factor
12 Rating, power factor, frequency
10
3.2 ZB. motor brake Demag B003 to B680 disk brakes are 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.
The diagrams show the function elements of the disk brakes, which are spring-
actuated with electromagnetic release.
When the voltage supply to the brake coil is interrupted, the brake is applied. This
operating principle is also known as a fail-safe brake.
Brakes B003 to B680 can be released by a rectifier integrated in the terminal box
of the motor. For brake sizes B003 to B050 also by applying DC voltage direct to
the brake coil.
Two brake sizes are available for each motor frame size to cover a large brake
torque range for various applications.
B 003 DC brake B007 - B680 DC brakes
1 345 6 7 1 2 8 3 4 5 6 14 7
8 9 10 11 12 13 14 15 11 13
42282444.eps 41687356.eps
1 Brake end cap 6 Electro-magnet 11 Distance spring

2 Engaging stirrup 7 Radial shaft sealing ring 12 Sealing washer
3 Brake disk 8 Friction plate 13 Adjusting nut
4 Friction plate 9 Sleeve 14 Brake spring
5 Stop plate 10 Grub screw 15 Collared pin
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11
4 Installation
4.1 Checking the Before installing the motor, check whether it has suffered any damage during trans-
portation or while in storage, such as corrosion, leaks, deformation or breakage.
condition of the
Do not clean motors with compressed air.
motor
4.2 Check the installation The standard motor is suitable for operation in normal industrial conditions. If the
ambient temperature, atmosphere or humidity are other than indicated on the
location rating plate, the motor must only be operated with special equipment or features
(see rating plate).
Coolant temperature: from –20°C to +40°C
Installation height: up to 1,000m above sea level
The site at which the motor is installed must be designed in such a way that
• air may circulate to allow heat to be exchanged and the warm air is not
immediately inducted again,
• no residue from operating processes can accumulate on the motor, fall
between the drive elements or damage the sealing ring,
• the rating plate is accessible.
4.3 Installing the motor Before installing the motor, check that it will be operated in the mounting position
specified on the rating plate.
4.4 Special instructions If the motor is operated outdoors in vertical mounting position IM V1 or in an in-
clined mounting position with the shaft facing downwards, it should be protected
for installing the motor by a canopy.
For motors with condensation water openings which can be closed with a threaded
plug, the drain holes must be arranged at the lowest point of the motor as other-
wise water may enter. If the mounting position of the motor is changed and the
drain holes are no longer required, the openings must be permanently sealed.
4.5 Instructions for • You must be a trained electrician and familiar with the relevant accident preven-
tion regulations and codes of practice.
connecting the motor
• The motor and the supply line are disconnected from the supply.
• The frequency and voltage specified on the rating plate must correspond to the
line frequency and voltage.
The motor must be connected as described in section 7 “Motor/brake connection

diagrams”. The connection diagram is glued inside the terminal box lid.
Connecting pin threads in the terminal box

Motor frame size Pins
63, 71, 80, 90 A M4
90 B, 100 M5
112, 132, 160, 180 A M6
180 B, 200, 225 M8
When the three L1, L2 and L3 phases are connected in sequence to the motor
terminals U1, V1, W1, the motor will run in the clockwise direction when viewed
from the motor output shaft side corresponding to DIN EN 60034-8.
The same procedure is used for motors with several speeds.To change the
214228k2.indd/100709
direction of rotation of the motor, two of the three phase conductors must be
interchanged.
The instructions contained in section 5 “Commissioning” must be followed.

12
5 Putting into operation
5.1 Requirements Before the motor is put into service:

• the terminal box be must be closed,
• the fan cover must be fitted (as delievered),
• the line voltage and frequency specified on the rating plate must match the
given power supply,
• the motor must be checked for correct connection (check direction of rotation),
• heat must be able to dissipate (e.g. air vent slits must be free),
• the drive unit does not constitute a hazard (e.g. no hazards caused by rotating
or live parts).
• there are no other hazard sources.
5.2 Check when Check that:

commissioning • the motor runs correctly (e.g. no speed fluctuations or excessive noise develop-
ment),
• there is no extreme vibration.
5.3 Geared motors For geared motors, also refer to the gearbox assembly instructions.
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13
6 Maintenance and repair
6.1 Inspection before If defects or damage are detected, the motor must not be put into operation
or it must be taken out of service. It may only be put back into service when
starting work and the defect has been eliminated.
during operation
Check the motor for: Check Action
• External damage → Inform person responsible
• Unusual running noises → Inform person responsible
• Dirt accumulation → Remove dirt accumulation
6.2 Maintenance schedule

Maintenance schedule
Interval Component Maintenance See section
In accordance with the Brake Check brake of motors fitted with brake. 6.3.1 and 6.3.2
operating conditions, at
least every 3000 hours of
operation.
Every 10 000 hours of Motor Inspect the motor and clean the cooling air channels.
operation.
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14
6.3 B 003 - B680 brakes The following work may only be carried out by qualified personnel.
Observe relevant safety regulations and codes of practise and the instructions
contained in section 1.4 “Safety instructions”.
Options: • Sealing (covering tape), for brake sizes B003 - B680

• Reduced noise level (standard for B050 – B680 brakes)
• Manual brake release unit
• Micro-switches for brake monitoring
• Emergency-stop brake lining
See 6.4 “Options”.
Notes for B003 brakes:

• Manual brake release unit only available for B007 - B680 brakes.
• Micro-switches are not provided.
Note for B007 - B680 brakes:

The brake spring values refer to the motor design WITHOUT a manual
brake release unit.
Apart from wear, the brake is virtually maintenance-free.

The organic/mineral brake lining is designed in such a way that worn surface
particles are only given off as minimal abrasion. This built-in regeneration of the
brake lining surface ensures constant braking characteristics. It is advisable to
check air gap s1 at certain intervals. To ensure the brake releases reliably, air gap
s1 must be adjusted, as required.
Brake size B 003 B 007 B 020 B 050 B 140 B 280 B 680

Motor ZBA
Brake air gap s 1 min. 0,3 0,3 0,3 0,3 0,35 0,4 0,4
Brake air gap s 1 max. 1,0 0,65 0,65 0,65 1,3 1,3 1,3
Motor ZBF
Brake air gap s 1 min. 0,3 0,3 0,3 0,3 0,35 – –
Brake air gap s 1 max. 1,2 1,2 1,2 1,2 1,2 – –
When the brake is released (power applied to brake coil), the brake disk can be
freely turned.
It is only possible to give guide values for brake operation until adjustment as they
depend on the given operating conditions.
Brake size B 003 B 007 B 020 B 050 B 140 B 280 B 680
Motor Brake work WN until readjustment in Ws
ZBA 160 · 10 6 100 · 10 6 120 · 10 6 200 · 10 6 1000 · 10 6 1500 · 10 6 2500 · 10 6
ZBF 200 · 10 6 200 · 10 6 300 · 10 6 500 · 10 6 900 · 10 6 – –
When the brake has been adjusted several times, the remaining thickness bmin of
the brake disk must be checked.
B003 brake
The brake can be adjusted twice. After the second adjustment, check remaining
thickness b min of the brake disk at regular intervals.
This brake can only be checked visually.
B003-B680 brakes
The brake must be replaced when the remaining thickness is too small or wear
differs considerably between the two linings. A wear part set is available for re-
placement. In addition to the brake disk and the required small parts, the set also
214228k3.indd/100709
includes the assembly instructions.
B007-B680 brakes
The collared pins feature an easily visible marking which clearly indicates the
minimum dimension (see section 6.3.2).
15
Overhaul sets and wearing part sets are available for general overhauls.
ZBA motors
Overhaul set
Brake size ZBA 63 ZBA 80 ZBA 90 B ZBA 112A ZBA 160 ZBA 180B ZBA 225 Wearing part set
ZBA 71 ZBA 90A ZBA 100 ZBA 132 ZBA 180A ZBA 200
B 003 260 960 33 – – – – – – 260 962 33

B007 260 966 33 260 967 33 – – – – – 260 970 33
B020 – 260 971 33 260 972 33 – – – – 260 975 33
B050 – – 260 976 33 260 977 33 – – – 260 980 33
B 140 – – – 260 981 33 260 982 33 – – 260 984 33
B 280 – – – – 260 985 33 260 986 33 – 260 987 33
B680 – – – – – 260 988 33 260 989 33 260 990 33
ZBF motors
Overhaul set
Brake size Wearing part set
ZBF 63/71 ZBF 80 ZBF 90B ZBF 100 ZBF 112A ZBF 132
B 003 260 960 33 – – – – – 260 962 33
B007 1) 260 964 33 – – – – – 260 965 33
B020 – 260 973 33 260 974 33 – – – 260 975 33
B050 – – 260 978 33 260 978 33 260 979 33 – 260 980 33
B 140 – – – – 260 983 33 260 983 33 260 984 33
1) B007 as an option for ZBF if manual brake release and/or brake monitoring is required.
6.3.1 Removing and fitting the fan The fan cover and motor fan must be removed in order to check and adjust the
cover and fan brake air gap as well as to replace the brake disk.
Removing the fan cover and fan
Undo the four retaining screws Remove the retaining ring, if Remove the fan.
and remove the fan cover. required.
41431944.eps 41432144.eps 41432244.eps
Fitting the fan cover and fan

214228k3.indd/100709
Fit the fan and secure it with the retaining ring, if required. Fit the fan cover.
Tightening torque
ZB. 63 - 100 motors = 4 Nm
After assembly is complete, ensure the retaining ring clicks
ZB. 112-132 motors = 6 Nm
correctly into the slot in the shaft.
ZB. 160-225 motors = 10,5 Nm
41432144.eps 41431945.eps
16
6.3.2 Checking and adjusting the The air gap must be adjusted when the max. permissible value s1 has been
brake air gap s1 reached, (however, immediately if the brake no longer releases).
If the brake is not adjusted, it will no longer release after further wear. If the
motor then operates against the applied brake, the brake and motor may be
damaged.
Checking the remaining thickness of the brake disk

B003-B680 brakes
Brake size B003 B007 B020 B050 B140 B280 B680
Remaining thickness b min. 3,5 5 6 7 8,5 10 11
Condition
when new
B 007 - B 680
1) If armature disk edge (2) has reached the mark (x) on
collared pin (4), brake disk (3) must be replaced.
B 003: A check can only be carried out by measuring
the remaining thickness.
See section 6.3.32 for replacing the brake disk.
2) If the remaining thickness of the brake disk is within
Remaining the specified tolerances, check brake air gap s1 (see
thickness b Checking and adjusting the brake air gap).
min.
42028944.eps
Checking and adjusting the brake air gap

B003 brakes
Magnet assembly (9)
Feeler gauge
Brake disk (3)
Friction plate (14)
End cap (6)

9
α1
12 10 42029146.eps
Brake air gap s1min = 0,30 mm - s1max= 1,0 mm (ZBA)

Brake air gap s1min = 0,30 mm - s1max= 1,2 mm (ZBF)
Tighten magnet assembly (9) with the three hexagon nuts (10) uniformly
until the air gap is zero.
214228k3.indd/100709
Stop plate (1) Then loosen the three hexagon nuts (10) by angle α1 = 120°.
Check air gap s1 using a feeler gauge at three points around the circum-
Armature disk (2) ference.
If the measured result is within the specified range, the motor can be re-
41777344.eps assembled.If this is not the case, adjust again as required.
17
Checking and adjusting the brake air gap
B007-B680 brakes
Brake size B007 B 020 B 050 B 140 B 280 B 680
Motor ZBA
Brake air gap s 1 min. 0,3 0,3 0,3 0,35 0,4 0,4
Brake air gap s 1 max. 0,65 0,65 0,65 1,3 1,3 1,3
Motor ZBF
Brake air gap s 1 min. 0,3 0,3 0,3 0,35 – –
Brake air gap s 1 max. 1,2 1,2 1,2 1,2 – –
Tighten magnet assembly (9) with the three hexagon nuts (10) uniformly until the air gap is zero.
Loosen the three hexagon nuts (10) by angle α1 .
Brake size B007 B020 B050 B140 B280 B680

Motor ZBA
Adjusting angle α 1 120° 120° 90° 80° 70° 60°
Motor ZBF
Adjusting angle α 1 120° 120° 90° 80° - -
Check air gap s1 using a feeler gauge at three points around the Ensure that the stop plate is not damaged.
circumference.
If the measured result is within the specified range, the motor
can be re-assembled.
If this is not the case, adjust again as required.
ZBF motor
ZBA motor ZBF 63 / 71 motor
B020-B050 brakes
B007-B050 brakes B007 brakes
Magnet assembly (9) Magnet assembly (9)
Feeler gauge Feeler gauge

Brake disk (3) Brake disk (3)
Friction plate (7) Retaining plate for sealing tape (7) - only for IP55
End cap (6) End cap (6)
Stop plate (1) Stop plate (1)
Armature disk (2) Armature disk (2)
42288944.eps 42288844.eps 42029144.eps
ZBA motor ZBF motor

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

214228k3.indd/100709
Stop plate (1)

Armature disk (2)
Armature disk (2) 41777444.eps 41777445.eps
18
6.3.3 Replacing the brake disk This work may only be carried out by specialist personnel.
Observe relevant safety regulations and codes of practise and the instructions
contained in section Safety instructions.
Damaged brakes may only be repaired by a Demag authorised workshop.
Please also refer to the information in section 6.4.
B003 brakes: Disassembly, assembly
Remove terminal box cover (11).

Undo hexagon nut (10) and remove washers (15), magnet
assembly (9) and covering tape (12).
42508644.eps
Remove stop plate (1), armature disk (2), distance springs

(5) and brake disk (3).
Check grub screws (4), sleeve (13) and braking surfaces for
wear
Replace worn or damaged parts.

“Damaged” should be understood to mean any de-
formation of stop plate (1), however small it may be.
42508344.eps
Mark “I” on friction plate (14) Disassembly, assembly

Grub screws/end cap (6) – if required
Mark on end cap (6)
Remove end cap (6).
Remove sleeve (13) and friction plate (14).
Unscrew the three defective grub screws (4).Fit new grub

screws (4).
Friction plate (14) is provided with mark “I”.
End cap (6) is also provided with a mark.
When fitting friction plate (14), ensure that the mark on
friction plate (14) is aligned with the mark on end cap (6).
Slide sleeve (13) onto grub screws (4).
Fit new end cap (6).
42508444.eps
214228k3.indd/100709
Tightening torque of the grub screws: 3Nm
19
Fit brake disk (3).
Recess on armature disk (2) The recess on the outer diameter and the bore hole on stop plate (1) must
be aligned with the mark on end cap (6) when fitting armature disk (2).
Mark “I” on friction plate (14)
The machined surface of armature disk (2) is the opposite surface of the
brake disk.
Mark on end cap (6)
Bore hole
on stop
plate (1)
Ensure that stop plate (1) is not deformed and lies
absolutely flat on armature disk (2).
Ensure that stop plate (1) does not jam between
screw (4), sleeve (13) and armature disk (2).
42508344.eps
B007-B680 brakes Disassembly, assembly
Remove terminal box cover (11).

Undo hexagon screw (10) and remove magnet assembly (9).
42022544.eps
Only for ZBA motors

O-ring (14) must also be replaced when brake
disk (3) is replaced.
Brake disk (3)
O-ring (14)
42288144.eps
Remove stop plate (1), armature disk (2), distance springs (5), brake
disk (3) and O-ring (14) (O-ring 14 only for ZBA motors).
Check collared pins (4) and braking surfaces for wear

214228k3.indd/100709
Replace worn or damaged parts.

“Damaged” should be understood to mean any de-
formation of stop plate (1), however small it may be.
42556944.eps
20
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

Retaining plate (7) is only fitted on
units with IP55 enclosure.
Fit retaining plate (7) with collared
42287944.eps pins (4).
Collared pin tightening torques

Cast-iron end cap 2,3 Nm 4 Nm 9 Nm 30 Nm 70 Nm 140 Nm
Tightening torque
Aluminium end cap 3,8 Nm - - - - -
Bore hole on stop plate (1)
Mark “I” on armature disk (2) Fit brake disk (3).

Mark “I” and the bore hole on stop plate (1) must be aligned with the mark
Mark on end cap (6) on end cap (6) when fitting armature disk (2).
Ensure that stop plate (1) is not deformed and lies

absolutely flat on armature disk (2).
Ensure that stop plate (1) does not jam between
collared pin (4) and armature disk (2).
42288144.eps
214228k3.indd/100709
21
Also to be considered when fitting B007 - B680 brakes on ZBA motors:
1) Fit O-ring (14) 1) Fit O-ring (14) onto the carrier.

2) Fit brake disk (3).
O-ring retaining groove
3) Push brake disk (3) into position.
O-ring (14)
Noticeable resistance has to be overcome to push O-ring (14) out of the
retaining groove. This point of resistance clearly indicates that O-ring (14)
is correctly fitted in the recess of brake disk (3).
Brake disk (3) may only be moved in the direction of the brake-side end
Carrier cap (see “Direction of assembly”). If brake disk (3) is pulled back by more
than 1,4 mm, O-ring (14) will roll out of the recess in brake disk (3) (repeat
Motor shaft the process if the disk is pulled back by more than 1,4 mm).
In this case, the damping effect will then no longer be ensured.
42561144.eps
2) Fit brake disk (3)
Brake disk (3)
O-ring (14)
42561044.eps
3) Push brake disk (3) into position
Direction of
assembly
42560944.eps
214228k3.indd/100709
22
6.3.4 Brake spring arrangement
and associated brake torques
B003 brakes on ZBA/ZBF motors
Push distance spring (5) onto grub screws (4).

Brake spring (8)
X 11 Place brake springs (8) into magnet assembly (9).
Insert covering tape (12) into the groove of end cap (6).
Push magnet assembly (9) and disks (15) over grub screws (4) and
secure with hexagon nut (10).
When fitting magnet assembly (9) ensure that covering tape (12)
engages the groove of magnet assembly (9).
Then tighten magnet assembly (9) with the three hexagon nuts (10)
uniformly until the air gap is zero. Then loosen the three hexagon
nuts (10) by angle α1 = 120°.
X
Check air gap s1 using a feeler gauge at three points around the
circumference. If the measured result is within the specified range,
the motor can be re-assembled.
See section 6.3.2 for checking/adjusting the brake air gap.
10 15 9 8 12 4 5 6 Pull the connecting cable of magnet assembly (9) back into the
42508244.eps
optional terminal box.Fit terminal box cover (11).
Arrangement of brake springs (8)
Brake torque Number of brake springs Ident. no.

Nm White Red Blue Yellow
2,5 3 - - - 260 010 84
1,9 - 3 - - 260 011 84
1,4 - - 3 - 260 027 84
0,9 - - - 3 260 013 84
B007-B680 brakes on ZBA motors
Push distance spring (5) onto collared pins (4).

Place brake springs (8) into magnet assembly (9).
See table below for arrangement of brake springs (8).
Brake Push magnet assembly (9) over collared pins (4) and secure with
hexagon nut (10).
spring (8)
Tighten magnet assembly (9) with the three hexagon nuts (10) uniformly
until the air gap is zero.
Check air gap s1 using a feeler gauge at three points around the circum-
ference. If the measured result is within the specified range, the motor
can be re-assembled.
Pull the connecting cable of magnet assembly (9) back into the terminal
box.
42022444.eps
Fit terminal box cover (11).
Brake size B 007 B 020 B 050 B 140 B 280 B 680
Adjusting angle α1 120° 120° 90° 80° 70° 60°

214228k3.indd/100709
Brake spring Ident. no.
White spring 260 110 84 260 210 84 260 310 84 260 410 84 260 510 84 260 610 84
Red spring 260 111 84 260 211 84 260 311 84 260 411 84 260 511 84 260 611 84
Blue spring 260 127 84 260 227 84 260 327 84 260 427 84 – –
23
Arrangement of brake springs for ZBA motors not fitted with a manual brake release unit

Quantity of springs Brake torque MB in Nm
For spring arrangement see item
White Red Blue
6 0 0 5 7,6 20 50 140 280 680

4 2 0 6 5,9 16 39 105 220 530
3 3 0 7 5,1 13 33 94 185 450
3 0 0 8 3,8 10 25 70 140 340
2 2 0 9 3,4 9 22 62 125 300
0 6 0 10 2,5 6,6 17 47 93 230
0 4 0 11 1,7 4,4 11 31 62 150
0 3 0 12 1,3 3,3 8,3 23 46 115
0 4 2 13 2,3 – – – – –
0 0 6 14 1,8 – – – – –
0 0 4 15 1,2 – – – – –
0 0 3 16 0,9 – – – – –
Arrangement of brake springs for ZBA motors fitted with a manual brake release unit
Brake size B 007 B 020 B 050 B 140 B 280 B 680

Quantity of springs Brake torque MB in Nm
For spring arrangement see item
White Red Blue
6 0 0 5 7,6 20 50 140 280 680
4 2 0 6 5,9 16 39 105 220 530
3 3 0 7 5,1 13 33 94 185 450
3 0 0 8 3,8 10 25 70 140 340
2 2 0 9 3,4 9 22 62 125 300
0 6 0 10 2,5 6,6 17 47 93 230
0 4 1 17 1,7 4,4 11 31 62 150
0 3 1 18 1,3 3,3 8,3 23 46 115
0 5 1 19 2,3
0 1 5 20 1,8
0 0 5 21 1,2
0 0 4 22 0,9
214228k3.indd/100709
24
Arrangement of brake springs for ZBA motors
5) 6) 7) 8) 9)
6 ws 4 ws, 2rt 3 ws, 3 rt 3 ws 2 ws, 2 rt
10) 11) 12) 13) 14)
6 rt 4 rt 3 rt 4 rt, 2 bl 6 bl
15) 16) 17) 18) 19)
4 bl 3 bl 4 rt, 1bl 3 rt, 1bl 5 rt, 1bl
20) 21) 22)
1rt, 5 bl 5 bl 4 bl
= Bore hole = ws, = rt, = bl,

empty white spring red spring blue spring
42506846.eps
214228k3.indd/100709
25
B007, B020, B050, B140 brakes for ZBF motors
Push distance spring (5) onto collared pins (4).

Place brake springs (8) into magnet assembly (9).
See table below for arrangement of brake springs (8).

Brake Push magnet assembly (9) over collared pins (4) and secure with
spring (8) hexagon nut (10).
Tighten magnet assembly (9) with the three hexagon nuts (10)
uniformly until the air gap is zero.
Check air gap s1 using a feeler gauge at three points around the
circumference. If the measured result is within the specified range,
the motor can be re-assembled.
Pull the connecting cable of magnet assembly (9) back into the
terminal box.
42022444.eps Fit terminal box cover (11).
Brake size B 007 B 020 B 050 B 140

Adjusting angle α1 120° 120° 90° 80°
Brake spring Ident. no.
Red spring 260 111 84 260 211 84 260 311 84 260 411 84
Blue spring 260 127 84 260 227 84 260 327 84 260 427 84
Arrangement of brake springs for ZBF motors not fitted with a manual brake release unit
Brake size B 007 B 020 B 050 B 140

Quantity of springs For spring arrangement see
Brake torque M B in Nm
Red Blue item
4 2 26 2,3 5,6 13 37
4 0 27 1,7 4,4 11 31
3 0 28 1,3 3,3 8,3 23
0 6 29 1,8 (3,3) 6,3 18
0 4 30 1,2 2,2 4,2 12
0 3 31 0,9 1,7 3,2 8,8
Arrangement of brake springs for ZBF motors fitted with a manual brake release unit
Brake size B007 B 020 B 050 B 140

Quantity of springs For spring arrangement
Brake torque M B in Nm
Red Blue see item
5 1 32 2,3 5,6 13 –
5 0 33 – – – 37
4 1 34 1,7 4,4 11 31
3 1 35 1,3 3,3 8,3 23

214228k3.indd/100709
1 5 36 1,8 (3,3) 6,3 –
1 4 37 – – – 18
0 5 38 1,2 2,2 4,2 12
0 4 30 0,9 1,7 3,2 8,8

26
Arrangement of brake springs for ZBF motors
26) 27) 28) 29) 30)
4 rt, 2 bl 4 rt 3 rt 6 bl 4 bl
31) 32) 33) 34) 35)
3 bl 5 rt, 1 bl 5 rt 4 rt, 1 bl 3 rt, 1 bl
36) 37) 38)
1rt, 5 bl 1rt, 4 bl 5 bl
= Bore hole = rt, = bl,

empty red spring blue spring
42506946.eps
6.3.5 Bolt tightening torques The bolts on Demag Z.. range motors must be tightened with the torques given in
the table below. This also applies when high tensile bolts are used.
Bolt tightening torques
For hexagon socket bolts to DIN 912 and to DIN 6912 for IM B 14 flange mounting
Bolt size M5 M6 M8 M 10 M 12 M 16
Tightening torque 6,2 Nm 10,5 Nm 25 Nm 50 Nm 86 Nm 215 Nm
For VERBUS RIPP self-locking bolts for • IM B 3 foot mounting

• IM B 5 flange mounting
Bolt size M5 M6 M8 M 10 M 12 M 16
Tightening torque for
7,5 Nm 14 Nm 30 Nm 65 Nm 100 Nm 270 Nm
cast iron
Tightening torque for
214228k3.indd/100709
9 Nm 18 Nm 45 Nm 75 Nm – –
cast aluminium
Tighten the fastening screws of the terminal box cover to a torque of

2,5 - 3 Nm. 27
6.4 Options The following options are possible:
• Sealing (covering tape) for IP55, brake types B003 - B680
• Reduced noise level
– Option brake types B007 - B050
– Standard for brake types B140 - B680
• Manual brake release unit
Manual brake release is only avaliable for B 007 - B680 brakes, not for B003
brakes.
• Micro-switches
A micro-switch arrangement is only possible for B007 - B680 brakes, not for
B003 brakes.
• Emergency-stop brake lining
6.4.1 Sealing for B 003 - B680

brakes, IP 55
Removing the covering tape
41766444.eps 41766544.eps 41766644.eps
Undo the screws retaining the terminal • Remove the terminal box cover. Remove the covering tape, if necessary, use
box cover. • Disconnect the brake power supply cable. a suitable tool, e.g. a screwdriver.
• Pull the brake power supply cable out of
the terminal box.
Fitting the covering tape
41766644.eps 41766544.eps 41766444.eps
Replace the covering tape, if necessary, use • Insert the brake power supply cable into Close the terminal box cover by tightening
214228k3.indd/100709
a suitable tool, e.g. a screwdriver. the terminal box. 4 screws. Tighten the torques in accordance
• Connect the brake power supply cable. with the “Bolt tightening torques” table in
• Fit the terminal box cover. 6.3.5.
• Ensure the seal is correctly seated.
28
6.4.2 Reduced noise level See section 6.3.3 for “Replacing the brake disk”
→ Fitting the brake
6.4.3 Manual brake release unit For motors fitted with a manual brake release unit, see also the “Additional
equipment for brakes, ZBA - ZBF motor range” assembly instructions, ident no.
214 041 44.
6.4.4 Micro-switches For motors fitted with integrated micro-switches, see also the “Additional equip-
ment for brakes, ZBA - ZBF motor range” assembly instructions, ident no.
214 041 44.
6.4.5 Emergency-stop brake lining For special applications, when the permissible friction per switching operation
is exceeded, an emergency-stop brake lining can be used for brake sizes B007
– B680 for ZBA 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
counter-surface must be expected.
Brake disks fitted with an emergency-stop brake lining are marked by a red dot
and the number 19 impressed in the brake lining carrier.
214228k3.indd/100709
29
7 Motor/brake connection diagrams
7.1 Brake control Various control modules are available which are fitted in the brake motor terminal
box as standard for controlling Demag B003 to B680 disk brakes with DC magnets.
B003 to B680 brakes All control modules feature varistor protection against overvoltage at the AC input
and on the switching contact terminal as standard.
For separate supply from the installation control, and when the control modules
are fitted in the switchgear cabinet, an additional varistor must be connected to the
brake connection in the terminal box of the brake motor.
Brakes up to size B050 for ZBA motors and B140 for ZBF motors can also be
supplied with 24 V DC from the installation power supply.
GF and GP brake rectifiers can be used parallel to the motor winding for pole-
changing motors.
GE, GS and GP brake rectifiers can be fed separately with alternating current or
connected parallel to the motor winding.
All brake rectifiers are approved for operation up to a max. connection voltage
of 500 V AC. AC or DC brake control is possible with GE GP and GS rectifiers
depending on the connection of the brake.
The control system is of modular design. SE or VE modules for fast DC interrup-
tion of the brake current can be added to brake motors fitted with GE, GS or GP
brake rectifiers, also at a later date, without the need for additional cables and
switching devices.
GF brake rectifiers feature integrated DC control as standard.
GU control modules are controlled in the DC circuit by means of a 24 V/DC control
voltage from the installation or inverter.
DC control should generally be provided for ZBF motors.
If ZB cylindrical rotor brake motors are operated together with inverters, the brake
must be provided with a separate power supply and control.
Supply and brake voltage
U line [AC] U brake [DC]
230 V 104 V
400 V 180 V
Operation with frequency inverters

If ZB cylindrical rotor brake motors are operated together with inverters, the
brake must be provided with a separate power supply and control.
Brake control module overview

Assignments
Excitation modules Switch-off modules Brief description
Type Type Component Function
GE - Brake rectifier Normal excitation
GP - Brake rectifier Normal excitation for pole-changing motors
GS - Brake rectifier High-speed excitation
Normal excitation for pole-changing motors and motor current-

GF - Combined module
dependent high-speed switch-off
214228k4.indd/100708
GU - Brake rectifier Control possible via 24 V/DC from installation or inverter
- SE Current relay Motor current-dependent high-speed switch-off
- VE Voltage relay Voltage-dependent high-speed switch-off

30
7.1.1 GE brake rectifiers (normal GE brake rectifiers are used for single-speed motors as standard, and for pole-
excitation) changing motors featuring a separate power supply up to brake size:
• B050 for ZBA motors
• B140 for ZBF motors.
The GE module mainly consists of a half-wave rectifier with an integrated free-
wheeling circuit.
Switching between terminal 1 or 2 and the brake coil is not permitted.
The connections to contacts 3 and 4 must not be interchanged for
connection of SE or VE modules.
Important: When used with a pole-changing motor, GE modules must be

provided with a separate power supply or according to diagram
037 860 84 (see section 7.5).
Note: No additional cables are necessary when SE or VE units are used.
7.1.2 GP brake rectifiers (normal GP brake rectifiers can be used parallel to the motor winding for pole-changing
excitation for pole-changing motors with separate windings. They are used up to brake size B050 for ZBA
motors) motors and B 140 for ZBF motors.
For this, it is necessary for both windings to be connected to one phase on the
terminal board (e.g. 1U & 2U). The advantage of using a GP brake rectifier
compared to a GE module is that no additional cables are required for the power
supply.
GP rectifiers mainly consist of two half-wave rectifiers which are connected
depending on the winding being used.

connection of SE modules.
Note: No additional cables are necessary when SE units are used.

214228k4.indd/100709
31
7.1.3 GS brake rectifiers GS brake rectifiers include a reversible rectifier and are used for ZBA motors with
(high-speed excitation) 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)
They can be used for single-speed motors as well as for pole-changing motors
with a separate power supply GS brake rectifiers can be used as an option for
brake sizes B003 to B050 (for ZBF to B140). In this case, a 2-phase supply at
terminals 5 and 6 is sufficient (overexcitation factor 2). This makes it possible to
achieve shorter brake release times and higher motor starting frequencies.
GS modules include a reversible rectifier which overexcites the brake for approx.
0,3 seconds to release it and then supplies it with the appropriate holding voltage
from a half-wave rectifier.
connection of SE modules.
Important: When used with a pole-changing motor, GS modules must be

provided with a separate power supply or according to dia-
grams 037 886 84, 038 001 84 and 038 017 84 (see section 7.5).
Note: No additional cables are necessary when SE or VE units are used.
To ensure the unit switches with over-excitation and, therefore, correct functioning,
the following minimum times must be maintained between switch-off and restart.
Switch-off method: Time
In the DC circuit 100 ms
With GS + VE / SE 250 ms
In the AC circuit 1,5 s
7.1.4 GF brake rectifiers (normal The GF combination module combines three functions in one unit and is supplied
excitation) together with the motor winding.
As standard, the GF brake rectifier is used for ZBF pole-changing motor frame
sizes 63 – 100 up to brake size B050. The motor current that flows through the
module from terminal 3 to 4 is detected for fast cut-off. When a specific level is not
longer attained, the GF module opens the DC circuit of the brake.
GF module function:
• Normal excitation of the brake similar to GP modules;
• Switch-off in the DC circuit by means of integrated motor current detection;
• Protection of the low-speed winding by means of an integrated varistor set.
GF modules must not be used together with an inverter (due to motor
current detection) and may only be supplied with voltages between 220 and
500 V AC.
Combinations with GE – VE or GS – VE modules must be used for inverter

operation.
214228k4.indd/100708
32
7.1.5 GU brake rectifiers GU brake rectifiers can be used as an option for brakes with a separate AC power
(normal excitation) supply up to brake size B050.
They are fitted in the brake motor terminal box as standard, but may also be alter-
natively used in a switchgear cabinet. The brake coil then has to be protected in
the motor terminal box against cut-off voltage peaks by a varistor.
The brake rectifier is controlled direct by means of a 24V/DC switching signal from
an installation or a frequency inverter.
The brake is switched on and off in the DC circuit, which enables a short brake ap-
plication time to be achieved.
It is not necessary to control the brake via the AC supply of the module with the
associated additional cabling and wiring requirement.
The brake application times correspond to those for switch-off in the DC circuit via
a contact.
7.1.6 SE current relays SE current relays can be combined with GE, GS and GP brake rectifiers. They are
(motor current-dependent used for rapid demagnetization of the brake to achieve fast brake application times
high-speed trip relay) without the need for additional wiring for brake switch-off in the DC circuit. SE cur-
rent relays are connected to one motor current phase. When the motor is switched
off, the relay demagnetizes the brake by opening the contact in the DC circuit. SE
current relays can be used for rated motor currents up to 50 A.
Important Operation together with inverters is not permitted.
We recommend the use of VE voltage relays for these
applications.
SE modules must not be used in the delta jumper for single-
speed motors
If the brake is to be released without motor current, it is also recommended that
the VE module be used instead of the SE. The grey and white connecting cables
of the SE module must be connected to terminals 3 and 4 of the GE, GS or GP
modules with the correct assignment.
7.1.7 VE voltage relays VE voltage relays can be combined with GE, GS and GP brake rectifiers. In con-
(voltage-dependent trast to SE current relays, VE voltage relays must only be used for brakes with a
high-speed trip relay) separate power supply. These modules may preferably be used for inverter-fed
motors and for brake release without motor current. They are used for high-speed
demagnetization of the brake to achieve fast brake application times without the
need for additional wiring for brake switch-off in the DC circuit. VE voltage relays
are connected to the brake power supply. The contact in the DC circuit is opened
when the brake is switched off.
The red, blue and white connecting cables of the VE module must be
connected to terminals 1,3 and 4 of the GE or GS modules with the correct
assignment.
GE and VE modules should be used for separate AC brake power supply in
combination with ZBF motors.
214228k4.indd/100709
33
Brake control module fields of application
GE, GP, GS brake rectifiers, GF, GU combined module
Brake voltage Brake size

U AC U DC
B003 B007 B020 B050 B140 B280 B680
V V
GE [3,0 A] GE [3,0 A] 1)
42 - 109 19 - 49 1)
GP [3,0 A] GP [3,0 A]
GE [1,5 A] GE [1,5 A] 1)
110 - 500 50 - 225 GP [1,5 A] GP [1,5 A] 1)
GS [1,0 A] GS [1,0 A]
190 - 500 86 - 225 GS [1,0 A]
260 - 500 117 - 225 GS [1,0 A]
220 - 500 99 - 225 GF [0,8 A] 1)
220 - 500 99 - 225 GU [0,8 A] 2)
SE and VE switch-off modules

Brake voltage Brake size
B003 B007 B020 B050 B140 B280 B680
U AC in V 42 - 500 54 - 500 190 - 500 260 - 500
U DC in V 19 - 225 24 - 225 86 - 225 117 - 225

VE 2A voltage relay
Modules
SE 2 A current relay
U AC = Brake control module input voltage

U DC = Brake control module output voltage - brake supply voltage
1) Only for use with ZBF motors.

2) Optional for brakes with separate AC power
supply.
Brake control module technical data
Voltage range Max. continuous

Module Part no. Remark
V /AC brake direct current I /A
260 892 84 110 ... 500 1,5
GE
260 890 84 42 ... 500 3
260 893 84 110 ... 500 1,5

GP
260 891 84 42 ... 500 3
GS 260 894 84 110 ... 500 3) 1 Overexcitaion factor: 2 or 2,5 1)
GF 260 943 84 220 ... 500 0,8 0,25 ... 16 A for ZBF 63 - 100
GU module controlled direct with a 24 V/DC
GU 260 957 84 220 ... 500 0,8 switching signal (I switch: approx. 10,2 mA)
from an installation or a frequency inverter
260 864 84 0,25 ... 4 A 2)
SE 260 870 84 42 ... 500 2 0,4 ... 16 A 2)
260 896 84 1,2 ... 50 A 2)
260 901 84 42 ... 149

VE 2
260 902 84 150 ... 500
214228k4.indd/100708
1) 2 leads - Overexcitation factor of 2

3 leads - Overexcitation factor of 2,5 required for ZBA motors from brake size B 140
2) 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)
34 3) Voltage range dependent on the brake size, see “Brake control module fields of application” table
7.2 Brake selection table
Assigned standard modules Standard brake torque Remark
ZBA ZBF
Supply voltage
Brake
V AC ZBA ZBF
Single speed or pole- Single speed Pole-changing
changing
42 - 109 GE [3 A] GE [3 A] + SE 1)
B003 ≤ 2,5 Nm ≤ 2,5 Nm
110 - 500 GE [1,5 A] GE [1,5 A] + SE 1)
42 - 109 GE [3 A] GE [3 A] + SE 1)
B007 ≤ 7,6 Nm ≤ 2,3 Nm 5)
110 - 500 GE [1,5 A] GE [1,5 A] + SE 1)
GF 3) 2)
42 - 109 GE [3 A] GE [3 A] + SE 1)
B020 ≤ 20 Nm ≤ 5,5 Nm
110 - 500 GE [1,5 A] GE [1,5 A] + SE 1)
42 - 109 GE [3 A] GE [3 A] + SE 1)
B050 ≤ 50 Nm ≤ 13 Nm
110 - 500 GE [1,5 A] GE [1,5 A] + SE 1)
42 - 109 – GE [3 A] + SE 1) GP [3 A] + SE 1)
B140 ≤ 140 Nm ≤ 37 Nm
110 - 500 GS GE [1,5 A] + SE 1) GP [1,5 A] + SE 1)
42 - 189 – – –
B280 ≤ 280 Nm – 4)
190 - 500 GS – –
42 - 259 – – –
B680 ≤ 680 Nm –
260 - 500 GS – –
1) SE modules are assigned in accordance with the motor rated current IN as shown below:
Motor rated current Module Part no.
IN ≤ 4 A 260 864 84
IN ≤ 16 A SE 260 870 84
IN ≤ 50 A 260 896 84
2) Power supply via a separate DC souce is possible without any limitation. Voltage range: 19 - 225 V DC
3) GF modules have a limited voltage range: 220 - 500 V AC
4) Power supply via a separate DC souce is not possible.
Exception: B140 brake with brake torque ≤ 37 Nm voltage range: 19 - 225 V DC
5) For ZBF travel motors fitted with the B003 as standard, the B007 is used for the manual brake release and/or brake monitoring options.
214228k4.indd/100709
35
7.2.1 Brake power consumption
400V AC (180V DC) supply voltage, control with brake modules

Temperature range: -20°C to +60°C
Size Excitaion with GE, GF or GP Excitation with GS module Excitation with GS module
module Overexcitation factor of 2 Overexcitation factor of 2,5
Release current Holding current Release current Holding current

I/A
I/A I/A I/A I/A
B003 0,11 0,22 0,11 0,28 0,11
B007 0,13 0,26 0,13 0,33 0,13
B020 0,22 0,44 0,22 0,55 0,22
B050 0,21 0,42 0,21 0,53 0,21
B140 1) 0,25 0,50 0,25 0,63 0,25
B280 1,13 0,45

Operation not permitted
B680 1,80 0,71
1) Brake size B140 may only be operated with a GE module or overexcitation factor of 2 up to a brake torque of 37 Nm.
• The release and holding currents are identical with normal excitation.
• Release currents for excitation with a GS module are applied for approx. 300 ms.
Separate brake control with 24V DC, temperature range: -20°C to +60°C
Size Current consumption I / A
B003 0,98
B007 0,90
B020 1,19
B050 1,75
B140 1) 1,73
1) Brake size B140 may only be operated up to a brake torque of 37Nm.
7.2.2 Electrical connection, brake

operation times
Depending on the type of connection, the release and braking operation of B003 to B680 DC brakes can generally be charac-
terized by the following values:
ZBA range brake operating times

Release times in ms Application times in ms
Size
t11 t12 t21 t22 t23
B003 75 60 175 55 75
B007 120 60 90 30 40
B020 130 90 40 20 30
B050 120 100 90 30 60
B140 --- 110 60 30 40

214228k4.indd/100708
B280 --- 140 300 90 130
B680 --- 140 300 150 190
36
ZBF range brake operating times
Release times in ms Application times in ms

Size
t11 t12 t21 t22 t23
B003 75 60 175 55 75
B007 1) 60 35 200 30 40
B020 60 40 300 50 60
B050 80 65 300 60 70
B140 110 90 350 100 100
The brake release and application times given are guide values for the maximum
brake torque. In the case of lower brake torques, these values may change,
particularly t21 for switch-off in the AC circuit.
t11 = Brake release time with normal excitation (GE, GP, GF, GU) 2)
t12 = Brake release time with high-speed excitation (GS) 2)
t21 = Brake application time for switch-off in the AC circuit
t22 = Brake application time for switch-off in the DC circuit (contact, GU)
t23 = Brake application time for switch-off in the DC circuit (SE, VE, GF)
Brake release times may be reduced using GS high-speed excitation modules with
which a higher voltage is temporarily applied to the brake coil when the brake is
turned on and the magnetic field is built up more quickly. Brake sizes B140 to B680
are generally controlled using the GS rectifier on ZBA motors.
Brake application times are highly dependent on the way in which the brake is
switched off.
• 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.
Demag rectifiers are protected against overvoltage at the switching contact by
varistors.
Interruption of the DC circuit between the module and the coil connections is
not permitted.
• Connection in the AC circuit: When the brake voltage is switched off, i.e. on the supply side before the rectifier,
an inductive coil current continues to flow through the rectifier diodes for a short
time. The magnet field decreases more slowly. The braking operation begins more
smoothly. This connection type is not suitable for hoist drives.
• Connection in the motor circuit: The rectifier is connected direct to the motor terminals. When the motor is switched
off, the residual motor voltage results in significantly longer switch-off times com-
pared to switch-off in the AC circuit.
Unless provided with additional switch-off in the DC circuit using a contact
or by the SE current relay, this type of connection is not suitable for drives
with overhauling loads, e.g. hoists, and may not be used in these applica-
tions.
Different excitation times result according to the connection. These times depend
on the one hand on the selected brake torque and, more decisively, on the brake
connection.
214228k4.indd/100709
1) For ZBF travel motors fitted with the B003 as standard, the B007 is used for the manual brake release and/or brake monitoring options.
2) Definition: The brake release time is the period which elapses until the full motor acceleration torque is attained.
37
7.3 Selection criteria The following criteria must be considered when selecting the connection diagram:
• Motor type ZBA, ZBF fitted with a brake or ZNA not fitted with a brake.
• 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)
• Motor designed for one or two speeds
• Common or separate power supply to motor and brake
• Control module selected:
– GE for normal excitation
– GS for high-speed excitation
– GP for normal excitation for pole-changing motors
– GF for pole-changing ZBF motors up to size 100
• Switch-off:
– in the DC circuit for short operating times (e.g. hoist drives, positioning drives)
– in the AC circuit for medium operating times (e.g. travel drives, conveyor
belts)
– in the motor circuit for stopping the motor in a non-critical time.
Refer to the following flow charts and selection tables.
Notes: • The motor and brake of inverter-fed drives must have separate
power supplies.
• SE modules must not be used with inverter-fed drives.
• Connection diagrams
– Connection diagram selection (flow chart) for line and inverter-
fed drives and related tables → section 7.5.
– Connection diagrams → Section 7.6
Diagrams shown in rising ident. number order
– Connection diagram arranged in the motor terminal box.
• Condition when supplied for inverter operation:

If the motor has been ordered for inverter operation, GE or GS
modules are NOT connected to the motor winding.
The brake control module must be provided with a separate AC
power supply.
• Designation of the terminal board
The terminal designations used in the connection diagrams are
printed on the white motor connecting leads. The designations on
the terminal board in the motor apply to single-speed motors with
6 connecting leads.
7.4 Z motor standard connection

diagrams to EN standards
7.4.1 ZNA standard motors, not

fitted with a brake Speed and winding type ZNA motor Connection diagram
Sizes
Single speed 63 – 225 020 323 84
Two speeds, separate windings (Y/Y) 63 – 132 020 332 84

214228k4.indd/100708
Two speeds, separate windings (Y/∆) 160 – 225 028 857 84
38
7.4.2 ZBA standard motors,
fitted with a brake
Single-speed motors (∆/Y)
ZBA motor Brake Control Line voltage

module
Connection Connection
Sizes ≤ 500V Example diagram > 500V Example diagram
Line: 525V
63 – 132 B003 – B050 GE 037 875 84 UBr = UM / √ 3 U M: 525V 037 857 84
Line: UBr: 300V
UBr = UM U M: 400V
GS three- UBr: Line: 525V
132 – 225 B140 – B680 phase 038 006 84 UBr ≤ 500V 1) U M: 525V 037 859 84 2)
supply UBr: 500V 1)
Double-speed motors, separate windings

Sizes 63 – 132 (Y/Y)
Sizes 160 – 225 (∆/Y)
ZBA motor Brake Control Line voltage
module
Sizes ≤ 500V Example Connection > 500V Example Connection
diagram diagram
63 – 132 B003 – B050 GE 037 860 84 038 425 84
Line: 400V Line: 525V
132 B140 GS three- UBr = UM U M: 400V 038 001 84 UBr ≤ 500V 1) U M: 525V 038 427 84
160 – 225 B140 – B680
phase UBr: 400V 038 017 84 UBr: 500V 1) 038 017 84 2)
supply
7.4.3 ZBF travel motors
Single-speed motors (∆/Y)

ZBF motor Brake Control Line voltage
module
diagram diagram
Line: Line: 525V
63 – 132 B003 – B140 GE + SE UBr = UM U M: 400V 037 882 84 UBr = UM / √ 3 U M: 525V 037 858 84
UBr: UBr: 300V
Double-speed motors, separate windings (Y/Y)

ZBF motor Brake Control Line voltage
module
diagram diagram
63 – 100 B003 – B050 GF Line: 038 337 84 Line: 525V 038 423 84
UBr = UM U M: 400V UBr = UM / √ 3 U M: 525V
112 – 132 B140 GP + SE 037 873 84 038 421 84
UBr: UBr: 300V
214228k4.indd/100709
UM Motor voltage
UBr Brake voltage
1) With transformer, separate supply
2) Separate supply
39
7.5 Connection diagram
selection
7.5.1 Line operation
Select connection dia-

gram for line operation
2 windings (Y/Y) Yes

up to size 132 Table 1
Voltage > 500 V
No
Yes
Special connection diagram Table 2
Yes No
Motor with brake ?
No
Yes Yes
1 line voltage? 1 speed ? Table 3
No
No
2 speeds Table 4
2 line voltages, dual-voltage

1 speed Table 5
motor
Yes Common power supply Yes

1 line voltage? Table 6
to motor and brake?
No No
DC brake B003 to B 680 Separate AC Yes

power supply? Table 7
No
2 line voltages, dual-voltage Separate DC power supply

motor Table 8
Common power supply Yes

DC brake B003 to B680 Table 9
to motor and brake?
No
Separate AC Yes
No
214228k4.indd/100708
Separate DC power supply Table 11
40 41808755.eps
Tables 1 – 2 Special connection diagrams
1 Motor with 2 windings ( Y/Y) up to size 132, line voltage > 500 V
Power supply Switch-off 1) Brake size Control modules in terminal box
ZBA ZBF GP GF 2 ) GE GS none
≤ B050 ≤ B140 038 420 84 – – – –

ms, ws, gs with contact
B140 – – – – – –
≤ B050 ≤ B140 038 421 84 – – – –

Common gs with SE
B140 – – – – – –
≤ B050 ≤ B140 – 038 423 84 – – –

internal
B140 – – – – – –
≤ B050 ≤ B140 – – 038 425 84 038 426 84 –

ws, gs with contact
B 140 – – – – 038 427 84 –
≤ B050 ≤ B140 – – 038 429 84 038 431 84 –

Separate, AC gs with SE
B 140 – – – – 038 433 84 –
≤ B050 ≤ B140 – – 038 430 84 038 432 84 –

gs with VE
B140 – – – – 038 434 84 –
Separate, DC gs with contact ≤ B050 ≤ B140 – – – – 038 428 84
– – none none – – – – 038 435 84
2 Description of special connection diagrams
Connection Windings Voltages Modules Switch-off 1) Special

diagram
038 021 84 2 (Y/Y) 1 GE + SE gs Only high speed is used
038 186 84 1 (YY/Y) 2 GE gs, ws, ms Brake coil for the high voltage
038 187 84 1 (YY/Y) 2 GE + SE gs Brake coil for the high voltage
038 338 84 2 (Y/Y) 1 GF gs Only high speed is used
038 422 84 2 (Y/Y) 1, > 500 V GE + SE gs Only high speed is used
038 424 84 2 (Y/Y) 1, > 500 V GF gs Only high speed is used, ZBF 63 – 100 motors
214228k4.indd/100709
1) gs In the DC circuit
ws In the AC circuit
ms In the motor circuit
2) Only for ZBF motors, sizes 63 – 100 41
Tables 3 – 5 Motors without a brake
3 Motor for one line voltage Motor type

Single speed
020 323 84
4 Motor for one line voltage Motor type
Two speeds
(separate windings)
Y/Y ∆/Y
020 332 84 028 857 84
5 Motor for two line voltages Motor type

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

brake power supply
Two speeds
(not suitable for inverter (separate windings)
Single speed
operation)
Y/Y ∆/Y
Switch- Switch- Brake size for Control module in the terminal box
off in ing ele-
ment
ZBA ZBF GE GS GU 3) GP GF 2) GE GS GU 3) GS GU 3)
DC circuit Contact ≤ B 050 ≤ B140 037 875 84 037 892 84 410 050 84 037 872 84 – 037 860 84 037 886 84 410 053 84 – 410 051 84
≥ B 140 – – 038 006 84 – – – – 038 001 84 – 038 017 84 –
SE 1) 2) ≤ B 050 ≤ B140 037 882 84 037 894 84 – 037 873 84 – – – – – –
≥ B 140 – – 038 008 84 – – – – – – – –
Internal – ≤ B050 – – – – 038 337 84 – – – – –
AC circuit Contact ≤ B 050 ≤ B140 037 875 84 037 892 84 – 037 872 84 – 037 860 84 037 886 84 – – –
≥ B 140 – – 038 006 84 – – – – 038 001 84 – 038 017 84 –
Motor circuit – ≤ B 050 ≤ B140 037 875 44 037 892 84 – 037 872 84 – – – – – –
≥ B 140 – – 038 006 84 – – – – – – – –
7 Separate AC brake power supply Motor type
Two speeds
(separate windings)
Single speed
Y/Y ∆/Y
Switch-off in Switch- Brake size for Control module in the terminal box
ing
element
ZBA ZBF GE GS GU 3) GE GS GU 3) GS GU 3)
DC circuit Contact ≤ B050 ≤ B140 037 875 84 037 892 84 410 050 44 037 860 84 037 886 84 410 053 84 – 410 051 84
≥ B140 – – 038 006 84 – – 038 001 84 – 038 017 84 –
SE 1) 2) ≤ B050 ≤ B140 037 882 84 037 894 84 – 037 861 84 037 887 84 – – –
≥ B140 – – 038 008 84 – – 038 002 84 – 038 018 84 –
VE 1) ≤ B050 ≤ B140 037 876 84 037 893 84 – 037 862 84 037 888 84 – – –
≥ B140 – – 038 007 84 – – 038 003 84 – 038 020 84 –
AC circuit Contact ≤ B050 ≤ B140 037 875 84 037 892 84 – 037 860 84 037 886 84 – – –
214228k4.indd/100708
≥ B140 – – 038 006 84 – – 038 001 84 – 038 017 84 –
1) Fitted in the terminal box

2) Not suitable for inverter operation
3) Up to B 050
42
8 Separate DC brake power supply Motor type
Single speed Two speeds

(separate windings)
Switch-off in Switching Brake size for No control module in the terminal box 4)
element
ZBA ZBF
DC circuit Contact ≤ B050 ≤ B140 037 897 84 037 898 84
9 Common motor and brake power supply Motor connection

(not suitable for inverter operation)
∆/Y YY / Y
Switch-off in Switching Brake size for Control module in the terminal box
element
ZBA ZBF GE GS GU 3) GE GS GU 3)
DC circuit Contact ≤ B050 ≤ B140 037 857 84 037 883 84 410 050 84 037 863 84 037 889 84 410 052 84
≥ B140 – – 037 859 84 – – 038 004 84 –
SE 1) 2) ≤ B050 ≤ B140 037 858 84 037 884 84 – 037 864 84 037 890 84 –
≥ B140 – – 037 865 84 – – 038 005 84 –
AC circuit Contact ≤ B050 ≤ B140 037 857 84 037 883 84 – 037 863 84 037 889 84 –
≥ B140 – – 037 859 84 – – 038 004 84 –
Motor circuit – ≤ B050 ≤ B140 037 857 84 037 883 84 – 037 863 84 037 889 84 –
≥ B140 – – 037 859 84 – – 038 004 84 –
10 Separate AC brake power supply Motor connection
∆/Y YY / Y
element
DC circuit Contact ≤ B050 ≤ B140 037 857 84 037 883 84 410 050 84 037 863 84 037 889 84 410 052 84
≥ B140 – – 037 859 84 – – 038 004 84 –
SE 1) 2) ≤ B050 ≤ B140 037 858 84 037 884 84 – 037 864 84 037 890 84 –
≥ B140 – – 037 865 84 – – 038 005 84 –
VE 1 ) ≤ B050 ≤ B140 037 876 84 037 893 84 – 037 881 84 037 896 84 –
≥ B140 – – 038 007 84 – – 038 014 84 –
AC circuit Contact ≤ B050 ≤ B140 037 857 84 037 883 84 – 037 863 84 037 889 84 –
≥ B140 – – 037 859 84 – – 038 004 84 –
11 Separate DC brake power supply Motor connection
∆/Y YY / Y
element
ZBA ZBF
DC circuit Contact ≤ B050 ≤ B140 037 897 84 037 899 84

214228k4.indd/100709

2) Not for inverter operation
3) Up to B050
4) GU modules can also be used for 24 V DC control voltage and/or 24 V DC brake coil voltage.
43
7.5.2 Inverter operation
Select connection diagram for

inverter operation
No
Motor with brake? Table 12
Yes
DC brake Separate AC Yes

B003 - B680
No
Separate DC power supply

Table 14
41808844.eps
Tables 12 - 14
12 Motor not fitted with a brake Motor type
Single speed Single speed

∆/Y YY / Y
020 323 84 020 337 84
13 Separate AC brake power supply Motor type

∆/Y YY / Y
element
DC circuit Contact ≤ B 050 ≤ B 140 037 875 84 037 892 84 410 050 84 037 863 84 037 889 84 410 052 84
≥ B 140 – – 038 006 84 – – 038 004 84 –
VE 1) ≤ B 050 ≤ B 140 037 876 84 037 893 84 – 037 881 84 037 896 84 –
≥ B 140 – – 038 007 84 – – 038 014 84 –
AC circuit Contact ≤ B 050 ≤ B 140 037 875 84 037 892 84 – 037 863 84 037 889 84 –
≥ B 140 – – 038 006 84 – – 038 004 84 –
14 Separate DC brake power supply Motor type

∆/Y YY / Y
element
ZBA ZBF
214228k4.indd/100708
DC circuit Contact ≤ B 050 ≤ B 140 037 897 84 037 899 84

2) GU modules can also be used for 24 V DC control voltage and/or 24 V DC brake coil voltage
3) Up to B050
44
7.6 Connection diagrams
Motor for one line voltage or dual voltage motor (1:√3)
Y high voltage
U2 V2 W2
∆ low voltage
For inverter operation, connect motor with

Y or ∆ connection according to inverter
settings.
U1 V1 W1
Y Δ
W2 U2 V2 W2 U2 V2
U1 V1 W1 U1 V1 W1
1L1 1L2 1L3 1L1 1L2 1L3 Motor supplied with:

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

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

switch-over
1U 1V 1W 2U 2V 2W
1L1* 1L2* 1L3*
2U 2V 2W
1U 1V 1W
1L1 1L2 1L3

Motor supplied with:
Motor connection ends connected to the
020 332 84 02033284.eps terminal board as shown.
Dual voltage motor (1:2)

YY low voltage
Y high voltage
U2 V2 W2
For inverter operation, connect motor with YY
or Y connection according to inverter settings.
U1 V1 W1 U5 V5 W5
YY Y
U2 V2 W2
U2 V2 W2 U5 V5 W5
U5 V5 W5
U1 V1 W1 U1 V1 W1
214228k5.indd/100709
1L1 1L2 1L3 1L1 1L2 1L3 Motor supplied with:

• Motor winding connected with Y connection.
• Jumper parts to connect the motor winding
with YY connection enclosed.
020 337 84 02033784.eps
45
Motor for one line voltage 1U, !V, !W for low speed
Pole-changing, separate winding 2U, 2V, 2W for high speed
* = Supply to high-speed winding via external

2V switch-over
1U 1V 1W 2U 2W
1L1* 1L2* 1L3*
2U 2V 2W
1U 1V 1W Motor supplied with:

Motor connection ends connected to the terminal
1L1 1L2 1L3 board as shown.
02885784.eps
028 857 84
Dual voltage motor (1:√3) A: Common power supply to motor and brake
Y high voltage ∆ low voltage
Brake coil rated for the low voltage. Not suitable for inverter operation.
U2 V2 W2
B: Separate power supply to brake

For inverter operation, connect motor with Y or ∆
connection according to inverter settings.
U1 V1 W1 BD1 BD2
Y Δ
W2 U2 V2 W2 U2 V2 GE
~ ~ - + Switch-off in the DC circuit
U1 V1 W1 U1 V1 W1
7 6 5 4 3 2 1 • Remove jumper between terminals 3 and 4.
• Connect a contactor between terminals 3 and 4.
1L1 1L2 1L3 1L1 1L2 1L3 A: U2 U1 BD2 BD1
S
B: 2L2 2L1 Switch-off in the AC circuit
03785784.eps
• Jumper between terminals 3 and 4.
Motor supplied with: • Contactor in the power line behind terminal 5.
• Jumper parts to connect the motor winding with Y or ∆ connection enclosed.
Motor current switch-off
• Brake connected to terminals 1 and 2 of the GE module.
• Jumper between terminals 3 and 4 of the GE module. Jumper between terminals 3 and 4
→ not possible for separate power supply to the
• Line operation: GE module connected with the motor winding according to variant A.
brake.
• Inverter operation or separate power supply to the brake:
– GE module not connected to the motor winding.
– Power supply by the customer according to variant B.
037 857 84
214228k5.indd/100709
46
Motor for one line voltage Brake coil rated for the phase voltage.
A: Common power supply to motor and brake
U2 V2 W2
Switch-off in the DC circuit dependent on motor

current
U1 V1 W1 BD1 BD2 Not suitable for inverter operation.
Y
W2 U2 V2 GE
SE
~ ~ - +
~ ~
U1 V1 W1
BK BK WH GY 7 6 5 4 3 2 1
Y U2 V2 WH GY
1L1 1L2 1L3 A: U2 U1 BD2 BD1

4 3 B: 2L2 2L1
GE SE
03785884.eps
• Jumper parts to connect the motor winding with Y connection enclosed.
• SE module connected to terminals 3 and 4 of the GE module.
• SE module connected with the motor winding according to variant Y.
• Separate power supply to brake:
037 858 84

Dual voltage motor (1:√3)
Brake coil rated for the low voltage. Not suitable for inverter operation.
U2 V2 W2

U1 V1 W1 BD1 BD2
Y Δ
Switch-off in the DC circuit
W2 U2 V2 W2 U2 V2 GS • Remove jumper between terminals 3 and 4.
~ ~ ~ - + • Connect a contactor between terminals 3 and 4.
U1 V1 W1 U1 V1 W1
7 6 5 4 3 2 1 Switch-off in the AC circuit
1L1 1L2 1L3 1L1 1L2 1L3 A: W1 U2 U1 BD2 BD1 • Contactors in the power lines behind terminals 5
S and 6.
B: 2L3 2L2 2L1
03785984.eps Motor current switch-off

Motor supplied with: Jumper between terminals 3 and 4
• Jumper parts to connect the motor winding with Y or ∆ connection enclosed. → not possible for separate power supply to the
• Brake connected to terminals 1 and 2 of the GS module. brake.
• Jumper between terminals 3 and 4 of the GS module.
214228k5.indd/100709
• Line operation: GS module connected with the motor winding according to variant A.
– GS module not connected to the motor winding.
037 859 84
47
Motor for one line voltage, pole-changing, separate windings A: Common power supply to motor and brake
* = Supply to high-speed winding via external switch-over
1U, 1V, 1W for low speed
2U, 2V, 2W for high speed Not suitable for inverter operation.
1U 1V 1W 2U 2V 2W BD1 BD2
1L2* 1L3* • Remove jumper between terminals 3 and 4.
2U 2V 2W GE
Switch-off in the AC circuit
~ ~ - +
1U 1V 1W • Jumper between terminals 3 and 4.
7 6 5 4 3 2 1 • Contactor in the power line behind terminal 5.
1L1 1L2 1L3 A: 1U 1L2 BD2 BD1

ext. S
1L1*
B: 2L2 2L1 03786084.eps
• Jumper parts to connect the motor winding enclosed.
• Jumper between terminals 3 and 4 of the GE module.
(1U connected to terminal 6; terminal 5 free).
Important The brake will not function without an external power supply to terminal 5
of the GE module.
037 860 84
Motor for one line voltage, pole-changing, separate windings

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


current
1L2* 1L3* Not suitable for inverter operation.
1U
2V 2W GE
2U SE
~ ~ - +
~ ~
A 1V 1W
BK BK WH GY 7 6 5 4 3 2 1
A 1U
2U
WH GY A = Intermediate terminal
1L1 1L2 1L3 2L2 2L1 BD2 BD1
1L1*
4 3
GE SE
03786144.eps

• Motor winding connected as in connection diagram (1U and 2U connected to one terminal)
214228k5.indd/100709
• SE module connected with the motor winding via intermediate terminal A and terminal 1U 2U
Important The brake will not function without a separate power supply to terminals 5
and 6 of the GE module.
48 037 861 84
Separate power supply to brake
switch-over.

X1 2U, 2V, 2W for high speed
RD
VE+ GE1 BD1

Voltage-dependent switch-off in the DC circuit
1L2* 1L3*
2U 2V 2W GE
VE ~ ~ - +
1U 1V 1W - + 7 6 5 4 3 2 1
WH BU RD
WH BU
1L1 1L2 1L3 2L2 2L1 BD2 X1

1L1*
GE4 GE3 X1
GE VE
03786244.eps

• VE module connected to terminals 1, 3 and 4 of the GE module.
Important: The brake will not function without a separate power supply to
terminals 5 and 6 of the GE module.
037 862 84
Dual voltage motor 1:2 A: Common power supply to motor and brake
Brake coil rated for the low voltage.
YY low voltage Y high voltage
U2 V2 W2
Not suitable for inverter operation.
U1 V1 W1 U5 V5 W5 BD1 BD2 B: Separate power supply to brake

For inverter operation, connect the motor with YY
YY Y or Y connection according to inverter settings.
U2 V2 W2
U2
U5
V2
V5
W2
W5
GE
~ ~ - +
U5 V5 W5
U1 V1 W1 U1 V1 W1
7 6 5 4 3 2 1
1L1 1L2 1L3 1L1 1L2 1L3 A: V5 U5
• Remove jumper between terminals 3 and 4
BD2 BD1
S • Connect a contactor between terminals 3 and 4
B: 2L2 2L1
03786344.eps
Motor supplied with: • Jumper between terminals 3 and 4
• Contactor in the power line behind terminal 5
• Jumper parts to connect the motor winding with YY connection enclosed. Motor current switch-off
• Brake connected to terminals 1 and 2 of the GE module. Jumper between terminals 3 and 4
• Jumper between terminals 3 and 4 of the GE module. → not possible for separate power supply to
• Line operation: GE module connected with the motor winding according to variant A. the brake.
214228k5.indd/100709

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

U2 V2 W2
Brake coil rated for the low voltage
U1 V1 W1 U5 V5 W5 BD1 BD2
YY Y Switch-off in the DC circuit dependent on motor

U2 V2 W2
U2 V2 W2 GE current
U5 V5 W5 SE ~ ~ - +
~ ~
A
U5
U1
V5
V1
W5
W1 A U1 V1 W1 BK BK WH GY 7 6 5 4 3 2 1 Not suitable for inverter operation.
WH GY
A U1
A: V5 U5 BD2 BD1
1L1 1L2 1L3 1L1 1L2 1L3
B: 2L2 2L1
4 3 SE
GE
A = Intermediate terminal
03786484.eps

• Jumper parts to connect the motor winding with YY connection enclosed.
• SE module connected with intermediate terminal A and the motor winding via U1.
037 864 84
Motor for one line voltage Brake coil rated for the phase voltage.
U2 V2 W2

current
U1 V1 W1 BD1 BD2

Y
W2 U2 V2 GS
SE
~ ~ ~ - +
~ ~
U1 V1 W1
BK BK WH GY 7 6 5 4 3 2 1
WH GY
Y U2 V2
1L1 1L2 1L3 A: W1 U2 U1 BD2 BD1
4 3 B: 2L3 2L2 2L1

GS SE
03786584.eps

• Brake connected to terminals 1 and 2 of the GS module.
• SE module connected to terminals 3 and 4 of the GS module.
214228k5.indd/100709
50 037 865 84
Common motor and brake power supply * = Supply to high speed winding via external
switch-over.


1L2* 1L3*
2U 2V 2W GP Switch-off in the DC circuit

~ ~ ~ - + • Remove jumper between terminals 3 and 4
1U 1V 1W • Connect a contactor between terminals 3 and 4
7 6 5 4 3 2 1
1L1 1L2 1L3 BD2 BD1 • Jumper between terminals 3 and 4
2V 1V 1U S
1L1* • Contactor in the power line behind terminal 5
03787284.eps
Jumper between terminals 3 and 4

• Brake connected to terminals 1 and 2 of the GP module.
• Jumper between terminals 3 and 4 of the GP module.
• GP module connected with the motor winding as in the connection diagram.
037 872 84

switch-over.


current
1L2* 1L3* Not suitable for inverter operation.
1U
2V 2W GP
2U SE
~ ~ ~ - +
~ ~
A 1V 1W
BK BK WH GY 7 6 5 4 3 2 1
A
1U
2U
WH GY
1L1 1L2 1L3 2V 1V A BD2 BD1
1L1*
4 3
GP SE
03787384.eps

• Motor winding connected as in connection diagram (1U and 2U connected to one terminal).
• SE module connected to terminals 3 and 4 of the GP module.
214228k5.indd/100709
• SE module connected with intermediate terminal A and the motor winding via terminal 1U 2U.
• GP module connected with the motor winding and intermediate terminal A as in the connection diagram.
037 873 84
51
Motor for one line voltage A: Common power supply to motor and brake
U2 V2 W2 Not suitable for inverter operation.

U1 V1 W1 BD1 BD2 For inverter operation, connect motor with Y or ∆
Y Δ
W2 U2 V2 W2 U2 V2 GE Switch-off in the DC circuit

• Remove jumper between terminals 3 and 4.
~ ~ - +
U1 V1 W1 U1 V1 W1
• Jumper between terminals 3 and 4
1L1 1L2 1L3 1L1 1L2 1L3 A: V1 U1 BD2 BD1 • Contactor in the power line behind terminal 5.
S
B: 2L2 2L1 Motor current switch-off
03787584.eps Jumper between terminals 3 and 4
→ not possible for separate power supply to
the brake.
037 875 84
Motor for one line voltage or dual voltage motor (1:√3) Y high voltage
∆ low voltage

U2 V2 W2
X1

RD
For inverter operation, connect the motor with Y or ∆
VE+ GE1 BD1
U1 V1 W1 BD1 BD2
Y Δ
W2 U2 V2 W2 U2 V2 GE
VE ~ ~ - +
U1 V1 W1 U1 V1 W1 - + 7 6 5 4 3 2 1
WH BU RD
WH BU
1L1 1L2 1L3 1L1 1L2 1L3 2L2 2L1 BD2 X1
4 3 X1
GE VE
03787644.eps

214228k5.indd/100709
52 037 876 84
Dual voltage motor 1:2 YY low voltage
Y high voltage

U2 V2 W2
X1
For inverter operation, connect motor with YY or Y
RD
VE+ GE1 BD1
YY Y
U2 V2 W2
U2 V2 W2 GE
U5 V5 W5
VE ~ ~ - +
U5 V5 W5
U1 V1 W1 U1 V1 W1 - + 7 6 5 4 3 2 1
WH BU RD
WH BU
1L1 1L2 1L3 1L1 1L2 1L3 2L2 2L1 BD2 X1
4 3 X1
GE VE
03788184.eps
• Motor winding connected with Y connection
037 881 84
Motor for one line voltage

A: Common power supply to motor and brake current
U2 V2 W2
U1 V1 W1 BD1 BD2
Y
W2 U2 V2 GE
SE
~ ~ - +
~ ~
U1 V1 W1
BK BK WH GY 7 6 5 4 3 2 1
Y U2 V2 WH GY
1L1 1L2 1L3 A: V1 U1 BD2 BD1

4 3 B: 2L2 2L1
GE SE
03788284.eps
214228k5.indd/100709

037 882 84 53
Dual voltage motor (1:√3) A: Common power supply to motor and brake
U2 V2 W2

U1 V1 W1 BD1 BD2
Y Δ
W2 U2 V2 W2 U2 V2 GS
~ ~ - + • Connect a contactor between terminals 3 and 4
U1 V1 W1 U1 V1 W1
1L1 1L2 1L3 1L1 1L2 1L3 A: U2 U1 BD2 BD1 • Contactor in the power line behind terminal 5
S
Motor supplied with: 03788384.eps Jumper between terminals 3 and 4
the brake.
037 883 84
Motor for one line voltage Brake coil rated for the phase
A: Common power supply to motor and brake voltage.
U2 V2 W2

current
U1 V1 W1 BD1 BD2
Y
W2 U2 V2 GS
SE
~ ~ - +
~ ~
U1 V1 W1
BK BK WH GY 7 6 5 4 3 2 1
WH GY
Y U2 V2
1L1 1L2 1L3 A: U2 U1 BD2 BD1
4 3 B: 2L2 2L1
GS SE
03788484.eps
214228k5.indd/100709

54 037 884 84
1L2* 1L3*
2U 2V 2W GS • Remove jumper between terminals 3 and 4.
~ ~ - + • Connect a contactor between terminals 3 and 4.
1U 1V 1W
1L1 1L2 1L3 A: 1U 1L2 BD2 BD1 • Contactor in the power line behind terminal 5.
ext. S
1L1*
B: 2L2 2L1
03788684.eps
• Line operation: GS module connected with the motor winding according to variant A
Important: The brake will not function without an external power supply to
terminal 5 of the GS module.
037 886 84

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


1L2* 1L3* current
1U
2V 2W GS
2U SE Not suitable for inverter operation.
~ ~ - +
~ ~
A 1V 1W
BK BK WH GY 7 6 5 4 3 2 1
1U
A 2U
WH GY
1L1 1L2 1L3 2L2 2L1 BD2 BD1

1L1*
4 3
GS SE
03788784.eps
• SE module connected with the motor winding via intermediate terminal A and terminal 1U 2U.
214228k5.indd/100709
Important: The brake will not function without a separate power supply to terminals 5
and 6 of the GS module.
037 887 84 55

X1
RD
VE+ GS1 BD1


1L2* 1L3*
2U 2V 2W GS
VE ~ ~ - +
1U 1V 1W - + 7 6 5 4 3 2 1
WH BU RD
WH BU
1L1 1L2 1L3 2L2 2L1 BD2 X1

1L1*
4 3 X1
GS VE
03788884.eps

• VE module connected to terminals 1, 3 and 4 of the GS module.
terminals 5 and 6 of the GS module.
037 888 84
Dual voltage motor (1:2) A: Common power supply to motor and brake
U2 V2 W2
For inverter operation, connect the motor with
YY Y YY or Y connection according to inverter settings
U2 V2 W2
U2
U5
V2
V5
W2
W5
GS
~ ~ - +
U5 V5 W5
U1 V1 W1 U1 V1 W1
7 6 5 4 3 2 1 Switch-off in the DC circuit
1L1 1L2 1L3 1L1 1L2 1L3 • Connect a contactor between terminals 3 and 4.
A: V5 U5 BD2 BD1
S Switch-off in the AC circuit
B: 2L2 2L1
03788984.eps
• Contactor in the power line behind terminal 5.
• Jumper parts to connect the motor winding with YY connection enclosed. → not possible for separate power supply to
• Brake connected to terminals 1 and 2 of the GS module. the brake.
214228k5.indd/100709
56 037 889 84
Dual voltage motor (1:2) YY low voltage
Y high voltage
U2 V2 W2

YY Y Switch-off in the DC circuit dependent on motor

current
U2 V2 W2
U2 V2 W2
SE
GS
U5 V5 W5
~ ~ ~ ~ - +
U5 V5 W5
A Not suitable for inverter operation.
A U1 V1 W1 U1 V1 W1 BK BK WH GY
7 6 5 4 3 2 1
A U1 WH GY
1L1 1L2 1L3 1L1 1L2 1L3 A: V5 U5 BD2 BD1

4 3
GS B: 2L2 2L1
SE
03789084.eps A = Intermediate terminal
037 890 84
U2 V2 W2
U1 V1 W1 BD1 BD2 B: Separate power supply to brake

Y Δ connection according to inverter settings
W2 U2 V2 W2 U2 V2 GS Switch-off in the DC circuit

~ ~ - + • Remove jumper between terminals 3 and 4.
U1 V1 W1 U1 V1 W1 • Connect a contactor between terminals 3 and 4.
7 6 5 4 3 2 1
1L1 1L2 1L3 1L1 1L2 1L3 A: V1 U1 BD2 BD1 • Contactor in the power line behind terminal 5.
S
03789284.eps
Motor supplied with: the brake.
214228k5.indd/100709

037 892 84 57
∆ low voltage

U2 V2 W2
X1 connection according to inverter settings.
RD
VE+ GS1 BD1 Voltage-dependent switch-off in the DC circuit

U1 V1 W1 BD1 BD2
Y Δ
VE ~ ~ - +
U1 V1 W1 U1 V1 W1 - + 7 6 5 4 3 2 1
WH BU RD
WH BU
1L1 1L2 1L3 1L1 1L2 1L3 2L2 2L1 BD2 X1
4 3 X1
GS VE
03789384.eps
037 893 84
Motor for one line voltage Switch-off in the DC circuit dependent on motor
current
U2 V2 W2
U1 V1 W1 BD1 BD2
Y
W2 U2 V2 GS
SE
~ ~ - +
~ ~
U1 V1 W1
BK BK WH GY 7 6 5 4 3 2 1
Y U2 V2 WH GY
1L1 1L2 1L3 A: V1 U1 BD2 BD1

4 3 B: 2L2 2L1
GS SE
Motor supplied with: 03789484.eps

214228k5.indd/100709

30
58 037 894 84
Y high voltage

U2 V2 W2
X1
RD
VE+ GS1 BD1

YY Y
U2 V2 W2
U2 V2 W2 GS
U5 V5 W5
VE ~ ~ - +
U5 V5 W5
U1 V1 W1 U1 V1 W1 - + 7 6 5 4 3 2 1
WH BU RD
WH BU
1L1 1L2 1L3 1L1 1L2 1L3 2L2 2L1 BD2 X1
4
GS 3 X1
VE
03789684.eps

037 896 84
∆ low voltage
Separate DC supply to brake

U2 V2 W2
SP1 SP2
U1 V1 W1 BD1 BD2
Y Δ
W2 U2 V2 W2 U2 V2
BD1 BD2
SP1 SP2
U1 V1 W1 U1 V1 W1
L+ L-
1L1 1L2 1L3 1L1 1L2 1L3
03789784.eps

• Brake connected to Euro terminals.
214228k5.indd/100709
Important: The brake will not function without a separate DC supply to the brake.
037 897 84 59
Separate DC supply to brake * = Supply to high-speed winding via

1U 1V 1W 2U 2V 2W
SP1 SP2
BD1 BD2
1L2* 1L3*
2U 2V 2W
BD1 BD2
1U 1V 1W SP1 SP2
L+ L-
1L1 1L2 1L3 03789884.eps
1L1*

037 898 84

Y high voltage
U2 V2 W2
Separate DC supply to brake

For inverter operation, connect the motor with YY or
U Y connection according to inverter settings.
U1 V1 W1 U5 V5 W5 SP1 SP2 BD1 BD2
YY Y
U2 V2 W2
U2 V2 W2 U5 V5 W5
BD1 BD2
SP1 SP2
U5 V5 W5
U1 V1 W1 U1 V1 W1
L+ L-
1L1 1L2 1L3 1L1 1L2 1L3
03789984.eps

214228k5.indd/100709
60 037 899 84
1L2* 1L3*
2U 2V 2W GS Switch-off in the DC circuit
~ ~ ~ - + • Remove jumper between terminals 3 and 4.

1U 1V 1W
7 6 5 4 3 2 1
1L1 1L2 1L3

A: 1U 1L3 1L2 BD2 BD1
ext. ext. S • Contactors in the power lines behind terminals 5
1L1*
B: 2L3 2L2 2L1 and 6.
03800184.eps
• Line operation: GS module connected with the motor winding according to variant A
(1U connected to terminal 7; terminals 5 and 6 free).
Important: The brake will not function without an external power supply to terminals 5
and 6 of the GS module.
038 001 84



1L2* 1L3*
current
1U
2V 2W GS
2U SE Not suitable for inverter operation.
~ ~ ~ - +
~ ~
A 1V 1W
BK BK WH GY 7 6 5 4 3 2 1
1U
A 2U
WH GY
1L1 1L2 1L3 2L3 2L2 2L1 BD2 BD1

1L1*
4 3 A = Intermediate terminal
GS SE
03800284.eps
• Motor winding connected as in connection diagram (1U and 2U connected to one
terminal).
214228k6.indd/100709
• SE module connected with the motor winding via intermediate terminal A and terminal
1U 2U.
Important: The brake will not function without a separate power supply to termi-
nals 5, 6 and 7 of the GS module.
038 002 84 61
* = Supply to high-speed winding via

X1
RD
1U 1V 1W 2U 2V 2W
VE+ GS1 BD1 BD1 BD2
1L2* 1L3*
2U 2V 2W GS
VE ~ ~ ~ - +
1U 1V 1W - + 7 6 5 4 3 2 1
WH BU RD
WH BU
1L1 1L2 1L3 2L3 2L2 2L1 BD2 X1

1L1*
4 3 X1
GS VE
03800384.eps

terminals 5, 6 and 7 of the GS module.
038 003 84
Dual voltage motor (1:2) A: Common power supply to motor and brake
U2 V2 W2
For inverter operation, connect the motor with
YY Y YY or Y connection according to inverter settings
U2 V2 W2
U2
U5
V2
V5
W2
W5
GS
~ ~ ~ - +
U5 V5 W5
U1 V1 W1 U1 V1 W1
7 6 5 4 3 2 1
1L1 1L2 1L3 1L1 1L2 1L3 A: W5 V5 U5 BD2 BD1
S • Connect a contactor between terminals 3 and 4.
B: 2L3 2L2 2L1 Switch-off in the AC circuit
03800484.eps • Jumper between terminals 3 and 4.
Motor supplied with: • Contactors in the power lines behind terminals 5
• Motor winding connected with Y connection. and 6.
• Jumper parts to connect the motor winding with YY connection enclosed. Motor current switch-off
• Brake connected to terminals 1 and 2 of the GS module. Jumper between terminals 3 and 4
• Jumper between terminals 3 and 4 of the GS module. → not possible for separate power supply to
214228k6.indd/100709
the brake.
62 038 004 84
Y high voltage
U2 V2 W2


YY Y
current
U2 V2 W2 GS
U2 V2 W2 U5 V5 W5 SE
~ ~ ~ - +
~ ~ Not suitable for inverter operation.
A
U5
U1
V5
V1
W5
W1 A U1 V1 W1 BK BK WH GY 7 6 5 4 3 2 1
A U1 WH GY
1L1 1L2 1L3 1L1 1L2 1L3 A: W5 V5 U5 BD2 BD1

4 3 B: 2L3 2L2 2L1
GS SE

03800584.eps
038 005 84
U2 V2 W2
U1 V1 W1 BD1 BD2
Y Δ For inverter operation, connect motor with Y or ∆
connection according to inverter settings
~ ~ ~ - +
U1 V1 W1 U1 V1 W1 • Remove jumper between terminals 3 and 4.
7 6 5 4 3 2 1 • Connect a contactor between terminals 3 and 4.
1L1 1L2 1L3 1L1 1L2 1L3 A: W1 V1 U1 BD2 BD1 • Jumper between terminals 3 and 4.
S
B: 2L3 2L2 2L1 • Contactors in the power lines behind terminals 5
03800684.eps and 6.
Motor supplied with: Jumper between terminals 3 and 4
• Jumper parts to connect the motor winding with Y or ∆ connection enclosed. → not possible for separate power supply to
• Brake connected to terminals 1 and 2 of the GS module. the brake.
214228k6.indd/100709

038 006 84 63
∆ low voltage

U2 V2 W2 For inverter operation, connect motor with Y or ∆
X1
RD Voltage-dependent switch-off in the DC circuit

U1 V1 W1 VE+ GS1 BD1 BD1 BD2
Y Δ
VE ~ ~ ~ - +
U1 V1 W1 U1 V1 W1 - + 7 6 5 4 3 2 1
WH BU RD
WH BU
1L1 1L2 1L3 1L1 1L2 1L3 2L3 2L2 2L1 BD2 X1
4 3 X1
GS VE
03800784.eps

038 007 84
Motor for one line voltage Switch-off in the DC circuit dependent on motor
current
U2 V2 W2
U1 V1 W1 BD1 BD2
Y
W2 U2 V2 GS
SE
~ ~ ~ - +
~ ~
U1 V1 W1
BK BK WH GY 7 6 5 4 3 2 1
WH GY
Y U2 V2
1L1 1L2 1L3 A: W1 V1 U1 BD2 BD1
4 3 B: 2L3 2L2 2L1
GS SE
03800884.eps
214228k6.indd/100709

64 038 008 84
Y high voltage
U2 V2 W2
X1
RD
U1 V1 W1 U5 V5 W5 VE+ GS1 BD1 BD1 BD2

YY Y
U2 V2 W2
U2 V2 W2 GS
U5 V5 W5
VE ~ ~ ~ - +
U5 V5 W5
U1 V1 W1 U1 V1 W1 - + 7 6 5 4 3 2 1
WH BU RD
WH BU
1L1 1L2 1L3 1L1 1L2 1L3 2L3 2L2 2L1 BD2 X1
4 3 X1
GS VE
03801484.eps

038 014 84

2V
1U 1V 1W 2U 2W BD1 BD2
1L2* 1L3*
2U 2V 2W GS Switch-off in the DC circuit

~ ~ ~ - + • Remove jumper between terminals 3 and 4.
1U 1V 1W • Connect a contactor between terminals 3 and 4.
7 6 5 4 3 2 1
1L1 1L2 1L3 • Jumper between terminals 3 and 4.
A: 1U 1L3 1L2 BD2 BD1
ext. ext. S • Contactor in the power line behind terminals 5
1L1*
B: 2L3 2L2 2L1 and 6.
03801784.eps
• Line operation: GS module connected with the motor winding according to variant A (1U
connected to terminal 7; terminals 5 and 6 free).
214228k6.indd/100709
038 017 84
65

2V
1U 1V 1W 2U 2W BD1 BD2
current
1L2* 1L3*
1U GS Not suitable for inverter operation.

2V 2W
2U SE
~ ~ ~ - +
~ ~
A 1V 1W
BK BK WH GY 7 6 5 4 3 2 1
1U
A 2U
WH GY
1L1 1L2 1L3 2L3 2L2 2L1 BD2 BD1 A = Intermediate terminal
1L1*
4 3
GS SE 03801884.eps
Important: The brake will not function without a separate power supply to terminals 5,
6 and 7 of the GS module.
038 018 84

* = Supply to high-speed winding via
2V
X1
RD
1U 1V 1W 2U 2W VE+ GS1 BD1 BD1 BD2

1L2* 1L3*
2U 2V 2W GS
VE ~ ~ ~ - +
1U 1V 1W - + 7 6 5 4 3 2 1
WH BU RD
WH BU
1L1 1L2 1L3 2L3 2L2 2L1 BD2 X1

1L1*
4 3 X1
GS VE
03802084.eps

214228k6.indd/100709

66 038 020 84
Common power supply to motor and brake

Only the high speed winding is used.

current
1L2 1L3

1U
2V 2W GE
2U SE
~ ~ - +
~ ~
A 1V 1W
BK BK WH GY 7 6 5 4 3 2 1
1U
A 2U
WH GY
1L1
A 2V BD2 BD1 A = Intermediate terminal
4 3
GE SE
03802184.eps

• GE module connected with the motor winding via intermediate terminal A and terminal 2V.
038 021 84
Motor for one line voltage or dual voltage motor (1:2) YY low voltage
Y high voltage
A: Common power supply to motor and brake.

U2 V2 W2 Brake coil only rated for the high voltage.

YY Y
B: Separate power supply to brake.
U2 V2 W2
U2
U5
V2
V5
W2
W5
GE
~ ~ - +
U5 V5 W5 or Y connection according to inverter settings.
U1 V1 W1 U1 V1 W1
7 6 5 4 3 2 1
1L1 1L2 1L3 1L1 1L2 1L3 A: V1 U1 BD2 BD1

S Switch-off in the DC circuit
B: 2L2 2L1
03818684.eps • Remove jumper between terminals 3 and 4
Motor supplied with: • Connect a contactor between terminals 3 and 4
214228k6.indd/100709
• Line operation: GE module connected with the motor winding according to variant A. Motor current switch-off
• Inverter operation or separate power supply to the brake: Jumper between terminals 3 and 4
– GE module not connected to the motor winding. → not possible for separate power supply to
– Power supply by the customer according to variant B. the brake.
038 186 84 67
Motor for one line voltage or dual voltage motor (1:2) YY low voltage
Y high voltage

U2 V2 W2
Brake coil only rated for the high voltage.

YY Y current
U2 V2 W2
U2 V2 W2 GE
U5 V5 W5 SE ~ ~ - + Not suitable for inverter operation.
~ ~
A
U5
U1
V5
V1
W5
W1 A U1 V1 W1 BK BK WH GY 7 6 5 4 3 2 1
WH GY
A U1
A: V1 A BD2 BD1
1L1 1L2 1L3 1L1 1L2 1L3
B: 2L2 2L1
4 3 SE
GE
03818784.eps
038 187 84

switch-over.


current

1L2* 1L3*
1U
2U 2V 2W GF
- +
A 1V 1W
7 6 5 4 3 2 1
1L1 1L2 1L3 1U BD2 BD1
1L1*
1W 1V 2V A 2U
03833784.eps

• Brake connected to terminals 1 and 2 of the GF module.
• GF module connected with the motor winding and intermediate terminal A as in the connection
214228k6.indd/100709
diagram.
68 038 337 84
Common power supply to motor and brake 2U, 2V, 2W for high speed

current
1L2 1L3
1U
2U 2V 2W GF A = Intermediate terminal
- +
A 1V 1W
7 6 5 4 3 2 1
1L1 1U BD2 BD1

2V A 2U
03833784.eps

diagram.
038 338 84

switch-over.
N0 N10 1U, 1V, 1W for low speed

Common motor and brake power supply
1L1*
1L1 1L2* 1L3*
2U
1U 2V 2W N10 GP
~ ~ ~ - +
1V 1W N0
7 6 5 4 3 2 1
1L2 1L3 2U BD2 BD1
N10 N0 1U S • Connect a contactor between terminals 3
and 4.
03842084.eps Switch-off in the AC circuit
Motor supplied with: Motor current switch-off

214228k6.indd/100709
Jumper between terminals 3 and 4.

• Jumper connected to terminals 3 and 4 of the GP module.
• GP module connected with the motor winding as in the connection diagram.
038 420 84 69
switch-over.
N0 N10

current

1L2* 1L3*
2U 2V 2W N10 GP
1U SE
~ ~ ~ - +
~ ~
A 1V 1W N0
BK BK WH GY 7 6 5 4 3 2 1
2U WH GY
A 1U
1L1 1L2 1L3 N10 N0 A BD2 BD1
1L1* 4 3
GP SE
03842184.eps
• SE module connected to terminals 3 and 4 of the GP module.
• GP module connected with the motor winding and intermediate terminal A as in the connection
diagram.
038 421 84
Motor for one line voltage, pole-changing, separate windings 2U, 2V, 2W for high speed
Common power supply to motor and brake
N0 N10

current

1L2 1L3
2U
2V 2W N10 GE
1U SE A = Intermediate terminal
~ ~ - +
~ ~
A 1V 1W N0
BK BK WH GY 7 6 5 4 3 2 1
2U WH GY
A 1U
1L1 A N10 BD2 BD1
4 3
GE SE
03842284.eps

214228k6.indd/100709

• SE module connected with intermediate terminal A and the motor winding via terminal 1U 2U.
• GE module connected with the motor winding via intermediate terminal A and terminal N10.
70 038 422 84
Motor for one line voltage, pole-changing, separate windings * = Supply to high speed winding via external
Common power supply to motor and brake switch-over.
N0 N10

current
1L2* 1L3*
GF
2U
2V 2W N10
1U - +
A 1V 1W N0 7 6 5 4 3 2 1
N0 N10 A
1U BD2 BD1
1L1 1L2 1L3 2U
1L1*
03842384.eps
diagram.
038 423 84
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.
N0 N10

current
1L2 1L3
GF
2U
2V 2W N10
1U - +
A 1V 1W N0 7 6 5 4 3 2 1
1L1 N10 A
1U BD2 BD1
2U
03842484.eps

214228k6.indd/100709
diagram.
038 424 84 71
switch-over.
Separate DC power supply to brake, maximum voltage 500 V AC
N0 N10

• Connect a contactor between terminals 3 and 4
1L1 1L2* 1L3*
2U
1U 2V 2W N10 GE
~ ~ - +
1V 1W N0
7 6 5 4 3 2 1
1L2 1L3 2L2 2L1 BD2 BD1

S 03842584.eps

and 6 o f t h e GE mo d u le .
038 425 84

Separate DC power supply to brake, maximum voltage 500 V AC switch-over.
N0 N10

1U 1V 1W 2U 2V 2W BD1 BD2 • Connect a contactor between terminals 3 and 4
1L1* Switch-off in the AC circuit
1L1 1L2* 1L3* • Jumper between terminals 3 and 4
2U
1U 2V 2W N10 GS
~ ~ - +
1V 1W N0
7 6 5 4 3 2 1
1L2 1L3 2L2 2L1 BD2 BD1

S
03842684.eps

214228k6.indd/100709

and 6 o f t h e GS mo d u le .
72 038 426 84

N0 N10

• Connect a contactor between terminals 3 and 4

1L1 1L2* 1L3*
2U
1U 2V 2W N10 GS
~ ~ ~ - +
1V 1W N0
7 6 5 4 3 2 1
1L2 1L3 2L3 2L2 2L1 BD2 BD1

S
03842784.eps

and 6 o f t h e GS mo d u le .
038 427 84
Separate DC supply to brake switch-over.
N0 N10
1U 1V 1W 2U 2V 2W SP1 SP2 BD1 BD2
1L1*
1L1 1L2* 1L3*
2U 2W
1U 2V N10
BD1 BD2
SP1 SP2
1V 1W N0
L+ L-
1L2 1L3
03842884.eps

214228k6.indd/100709

038 428 84 73
switch-over.
N0 N10 2U, 2V, 2W for high speed

current
1L2* 1L3*
2U 2V 2W N10 GE
1U SE
~ ~ - +
~ ~
A 1V 1W N0
BK BK WH GY 7 6 5 4 3 2 1 A = Intermediate terminal
2U
A 1U
WH GY
1L1 1L2 1L3 2L2 2L1 BD2 BD1

1L1*
4 3
GE SE
03842984.eps
Important: The brake will not function without a separate power supply to terminals 5 and 6
of the GE module.
038 429 84

N0 N10 2U, 2V, 2W for high speed
X1
RD
1U 1V 1W 2U 2V 2W VE+ GE1 BD1 BD1 BD2
1L1*
1L1 1L2* 1L3*
2U
2V 2W N10 GE
1U
VE ~ ~ - +
1V 1W N0 - + 7 6 5 4 3 2 1
WH BU RD
WH BU
1L2 1L3 2L2 2L1 BD2 X1
4 3 X1
GE VE
03843084.eps
214228k6.indd/100709
of the GE module.
74 038 430 84

N0 N10

current

1L2* 1L3*
2U GS
1U 2V 2W N10 SE
~ ~ - +
~ ~ A = Intermediate terminal
A 1V 1W N0
BK BK WH GY 7 6 5 4 3 2 1
2U
A 1U
WH GY
1L1 1L2 1L3 2L2 2L1 BD2 BD1

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

N0 N10

X1
RD
1U 1V 1W 2U 2V 2W VE+ GS1 BD1 BD1 BD2
1L1*
1L1 1L2* 1L3*
2U
2V 2W N10 GS
1U
VE ~ ~ - +
1V 1W N0 - + 7 6 5 4 3 2 1
WH BU RD
WH BU
1L2 1L3 2L2 2L1 BD2 X1
4 3 X1
GS VE
03843284.eps

214228k6.indd/100709

of the GS module.
038 432 84 75

N0 N10

current

1L2* 1L3*
2U
2V 2W N10 GS
1U SE
~ ~ ~ - +
~ ~ A = Intermediate terminal
A 1V 1W N0
BK BK WH GY 7 6 5 4 3 2 1
2U
A 1U
WH GY
1L1 1L2 1L3 2L3 2L2 2L1 BD2 BD1

1L1*
4 3
GS SE
03843384.eps

Important: The brake will not function without a separate power supply to terminals 5, 6 and
7 of the GS module.
038 433 84
switch-over.
N0 N10
X1 Voltage-dependent switch-off in the DC circuit
RD
1U 1V 1W 2U 2V 2W VE+ GS1 BD1 BD1 BD2
1L1*
1L1 1L2* 1L3*
2U 2V 2W N10 GS
1U
VE ~ ~ ~ - +
1V 1W N0 - + 7 6 5 4 3 2 1
WH BU RD
WH BU
1L2 1L3 2L3 2L2 2L1 BD2 X1
4 3 X1
GS VE
03843484.eps

214228k6.indd/100709

Important: The brake will not function without a separate power supply to terminals 5, 6 and
7 of the GS module.
76 038 434 84
switch-over.

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

Motor winding connected as in connection diagram (1U and 2U connected to one terminal)
038 435 84

U2 V2 W2

BD2
U1 V1 W1 BD1
Y Δ
W2 U2 V2 W2 U2 V2 GU
~ ~ + - - + Switch-off in the DC circuit
U1 V1 W1 U1 V1 W1
6 5 4 3 2 1 • Switched 24V DC power supply to control the
internal GU switching relay connected between
terminals 3 and 4.
1L1 1L2 1L3 1L1 1L2 1L3 A: V1 U1 + - BD2 BD1
B: 2L2 2L1 24V DC Switch-off in the AC circuit

• Permanent 24V DC power supply connected to
41005084.eps terminals 3 and 4 (not switched).
• Jumper parts to connect the motor winding with Y or ∆ connection enclosed. Motor current switch-off
• Brake connected to terminals 1 and 2 of the GU module. • Permanent 24V DC power supply connected to
• Terminals 3 and 4 of the GU module free (connect 24V DC). terminals 3 and 4 (not switched).
• Line operation: GU module connected with the motor winding according to variant A. → not possible for separate power supply to
the brake.
214228k6.indd/100709
– GU module not connected to the motor winding.

410 050 84 77
2V
1U 1V 1W 2U 2W BD1 BD2 Switch-off in the DC circuit
1L2* 1L3*
• Switched 24V DC power supply to control the
terminals 3 and 4.
2U 2V 2W GU
~ ~ + - - + Switch-off in the AC circuit
1U 1V 1W • Permanent 24V DC power supply connected to
6 5 4 3 2 1
terminals 3 and 4 (not switched).
1L1 1L2 1L3 A: 1U 1L2
ext.
+ - BD2 BD1
1L1*
B: 2L2 2L1 24V DC

41005184.eps
• Brake connected to terminals 1 and 2 of the GU module.
• Terminals 3 and 4 of the GU module free (connect 24V DC).
• Line operation: GU module connected with the motor winding according to variant A
terminal 5 of the GU module.
410 051 84
Dual voltage motor 1:2 A: Common power supply to motor and brake
U2 V2 W2
U1 V1 W1 U5 V5 W5 BD1 BD2 B: Separate power supply to brake

YY Y or Y connection according to inverter settings.
U2 V2 W2
U2
U5
V2
V5
W2
W5
GU
U5 V5 W5
~ ~ + - - +
U1 V1 W1 U1 V1 W1
6 5 4 3 2 1 Switch-off in the DC circuit
1L1 1L2 1L3 1L1 1L2 1L3 A: V5 U5 + - BD2 BD1 internal GU switching relay connected between
B: 2L2 2L1 24V DC
terminals 3 and 4
41005284.eps
• Permanent 24V DC power supply connected to
• Motor winding connected with Y connection. terminals 3 and 4 (not switched).
• Jumper parts to connect the motor winding with YY connection enclosed. • Contactor in the power line behind terminal 5
Permanent 24V DC power supply connected to
• Line operation: GU module connected with the motor winding according to variant A.
214228k6.indd/100709

– GU module not connected to the motor winding. → not possible for separate power supply to
– Power supply by the customer according to variant B. the brake.
78 410 052 84

1L2* 1L3*
terminals 3 and 4.
2U 2V 2W GU
~ ~ + - - + Switch-off in the AC circuit
1U 1V 1W • Permanent 24V DC power supply connected to
6 5 4 3 2 1
1L1 1L2 1L3 A: 1U 1L2
ext.
+ - BD2 BD1
1L1*
B: 2L2 2L1 24V DC
Motor supplied with: 41005384.eps
• Line operation: GU module connected with the motor winding according to variant A.
Important The brake will not function without an external power supply to terminal
5 of the GU module.
410 053 84
214228k6.indd/100709
79
7.7 Connecting tempera- Depending on the motor features, the connections for temperature monitoring and/
or brake monitoring are brought out on Euro terminals in the terminal box.
ture and brake moni-
The following connection designations are used:
toring devices
• PTC thermistor
– Switch-off: 1TP1 - 1TP2 and 2TP1 - 2TP2
– Warning: TP11 - TP12
Important: PTC thermistors to DIN 44081 are suitable for tripping devices with
2,5 V DC output voltage and 4 kΩ tripping resistance.
PTC thermistors may only be continuity tested with max. 2,5 V DC.
Do not use a buzzer (voltage peaks) or similar devices. The resist-
ance of one PTC thermistor is 20 ... 250 Ω at temperatures of –20°C
to ϑTNF – 20K. (TNF = rated operating temperature).
• Temperature detector (bimetallic switch): TB1 - TB2
• Brake monitoring
– Release monitoring: 1S3 - 1S2 - 1S1
Contact 2 (1S2 - 1S1) closed:
Brake not released, brake in applied position
Contact 4 (1S3 - 1S1 closed:
Brake released
– Adjustment monitoring: 2S3 - 2S2- 2S1
Contact 2 (2S2- 2S1) closed:
Brake must be adjusted
Contact 4 (2S3 - 2S1) closed:
Normal operating condition
The diagrams below show the most important single connections.

When several monitoring devices are used (such as PTC thermistors for the motor
and release monitoring for the brake), the individual circuits are combined in one
connection diagram which can be found inside the motor terminal box.
PTC thermistor PTC thermistor PTC thermistor PTC thermistor
3x
3x 3x 6x
Switch-off Switch-off 1 Warning Switch-off
1TP1 1TP2
TP1 TP2 P1 P2 TP11 TP12 TP1 TP2
P1 P2 P11 P12 P1 P2
3x
Switch-off 2
2TP1 2TP2
P21 P22
03781984.eps 03782084.eps 03782184.eps 03782384.eps
PTC thermistor Brake monitoring Brake monitoring Temperature detector

Release monitoring Adjustment monitoring
6x
Warning
214228k7.indd/100709
4 2 1 4 2 1
wh gn bn wh gn bn
TP11 TP12 TB1 TB2
1S3 1S2 1S1 2S3 2S2 2S1
P11 P12 P1 P2
03782784.eps 03781684.eps 03781784.eps 03782284.eps
80
8 Technical data
Function conditions for standard design

Conditions Z range
Transport temperature - 20 ... +40 °C
Storage temperature 0 ... +40 °C
Storage conditions dry, indoors
Ambient operating temperature - 20 ... +40 °C
Ambient conditions acid-free
Coolant Air
Coolant temperature max. +40 °C
Temperature rise limit of winding 105 K
Site altitude max. 1000 m above sea level
Air circuit Ensure by working clearance, unrestricted air intake
Type of enclosure IP54
Mounting arrangement Low vibration
Working clearance at fan end 150 mm at rear
Line voltage 400 V/50 Hz 480V/60Hz 500 V/50 Hz
Voltage tolerance ±10 % of the line voltage for short periods according to IEC 38
Maximum speeds in rpm
Motor frame size with operational braking Motor frame size with occasional
(line operation) emergency stops
(inverter operation)
ZBF 63 – 132 3600 – –
ZNA 63 – 100 5000 ZNA 63 – 100 5000
ZNA 112 – 132 4000 ZNA 112 – 132 4000
ZNA 160 – 180 A 3600 ZNA 160 – 180 A 3600
ZNA 180 B – 225 3000 ZNA 180 B – 225 3000
ZBA 63 – 100 5000

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

ZBA 160 – 180 A 3600
ZBA 160 – 180 A, with B 280 brake
2000
ZBA 180 B – 225 ZBA 180 B – 225 3000
214228k7.indd/100709
81
9 Troubleshooting
Item Problem Possible cause Solution

1 Motor does not start. Fuse has tripped. Replace fuse.
Power supply line interrupted. Check connections.
Motor protection has tripped. Check motor protection for correct seating.
Control defective. Check motor connection.
Brake does not release. See item 10 “Brake does not release”
2 Motor does not start or starts Motor for delta connection is connected in star. Correct motor connection.
slowly. Extreme voltage or frequency deviation from setpoint Improve quality of power supply; check power
value. supply line cross-section.
3 Motor will not start in star connec- Insufficient torque in star connection. If the delta starting torque is not too high, start
tion, only starts in delta connection. up direct in star connection; otherwise use larger
motor or special design (contact manufacturer).
Contact fault in star-delta starter. Eliminate fault.
4 Motor runs in wrong direction. Motor incorrectly connected. Swap two supply leads.
5 Motor hums and has high power Winding defective. Motor must be sent to specialist workshop for
consumption. repair.
6 Fuses trip or motor protection trips Short-circuit in the supply line. Eliminate short-circuit.
immediately. Short-circuit in the motor. Motor must be sent to specialist workshop for
repair.
Power supply leads incorrectly connected. Correct motor connection.
Short-circuit to earth in the motor. Motor must be sent to specialist workshop for
repair.
7 Extreme loss of speed under load. Overload. Measure power, use larger motor or reduce load,
if necessary.
Voltage drop. Use larger power supply line cross-section.
8 Excessive motor temperature rise Overload. Measure power, use larger motor or reduce load,
(measure temperature). if necessary.
Insufficient cooling. Improve cooling air circulation or clear air
circulation channels; fit separate fan, if necessary.
Separate fan not running. Check connection, correct, if necessary.
Ambient temperature too high Reduce power; use larger motor, if necessary.
Delta connection instead of star connection as specified. Correct motor connection.
Temporary two-phase operation. Intermittent electrical contact in the power supply
line.
Fuse has tripped. Replace fuse.
Mains voltage differs from the rated motor voltage Match motor to power supply voltage.
by more than 10%. Higher voltages are particularly
unfavourable for low-speed motors as their no-load
current is close to the rated current even at normal
voltage.
Duty type (S1 - S10, EN 60034-1) exceeded, e.g. starting Adapt operating conditions to corresponding motor
frequency is too high. duty type.
9 Excessive noise. Friction bearing distorted, dirty or damaged. Re-align motor, inspect friction bearings, replace if
necessary.
Rotating parts vibrating. Correct any imbalance.
Foreign bodies in cooling air circuit. Clean cooling air paths.
10 Brake does not release. Incorrect voltage applied to brake control unit Apply correct voltage (see rating plate).
Brake control unit failure. Replace brake control unit, check brake coil
(resistance), check switchgear components.
Maximum permissible air gap exceeded because the Adkust the brake (replace the complete brake
brake lining is worn out. lining carrier if the lining is worn out).
Voltage drop in the power supply line > 10 %. Ensure correct supply voltage is applied.
Brake coil short-circuit with the winding or housing. Replace complete brake with control unit
(specialist workshop), check switchgear
components.
11 Motor does not brake. Brake lining worn out. Replace the complete brake lining carrier.
214228k7.indd/100709
Manual brake release device incorrectly adjusted. Set adjusting nuts to correct setting.
Manual brake release device locked. Release lock, remove lever.
Incorrect brake torque. Change brake torque.
82
1 page(s) Page 1
EC conformity declaration
Ident. no.
Demag AC motor type Z, M
in accordance with EC directive 89/336/EEC, Appendix I, and 205 211 44
73/23/EEC, Appendix III Issue 1205 EN
Hereby we,
Demag Cranes & Components GmbH

Drives,
declare that the product
Demag AC motor
of the
Z, M
type of serial design, with or without the relevant gearbox, has been declared in
conformity with the provisions of the following relevant regulations:
EC EMC directive 89/336/EEC

amended by 92/31/EEC and 93/68/EEC
EC Low voltage Directive 73/23/EEC
amended by 93/68/EEC
Applied harmonised standards: #
EN ISO 12100 Safety of Machinery

EN 61000-6-2 Electromagnetic Compatibility, Resistance to Interference
in Industrial Environments
EN 61000-6-4 Electromagnetic Compatibility, Interference Emission in
Industrial Environments
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 Evaluation of Isolating Systems
EN 60529 Types of Enclosure (IP Code)
Wetter, 1 December 2005

Place and date of issue
#
ppa. Schulte ppa. Hoffmann
Engineering (Drives) Handling Technology BU
214228k7.indd/100709
# = Modifications compared to Class. no.

Normung
previous issue 715 IS 919
83
Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, D-58286 Wetter Subject to change. No liability accepted for errors or omissions.
Addresses
The current addresses of the sales offices in Germany and the subsidiaries and agencies worldwide can be found on the
Demag Cranes & Components homepage at
www.demagcranes.com ► Contact and Demag worldwide
Demag Cranes & Components GmbH

Drives
P.O. Box 67, D-58286 Wetter
Printed in Germany
Telephone +49(0)2335 92-5550 · Telefax +49(0)2335 92-2406

E-mail drives@demagcranes.com
www.demagcranes.com
Reproduction in whole or in part only with prior consent of Demag Cranes & Components, D-58286 Wetter Subject to change. Not liable for errors or omissions.

Ensamblaje Motor Z Demag

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Assembly instructions

100709 enEN 214 228 44 719 IS 919

Manufacturer Demag Cranes & Components GmbH

General documents Part No.

Catalogues / technical Data

Drive Designer Online www.demag-drivedesigner.com

Z motor spare part lists

5 Putting into operation 13

7 Motor/brake connection diagrams 30

You have purchased a Demag product. This equipment was manufactured in

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

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

0.5 Deﬁnitions Owner

Warning against dangerous electrical voltage

Operating hazard for the installation

Warning against dangerous electrical voltage

Putting motors into operation Do this only

Brief explanation of enclosures:

IP 54 Protection against harmful dust accumulation, protection against splashwater

IP 55 Protection against harmful dust accumulation, protection against hose-water

IP 65 Complete protection against dust accumulation, protection against hose-water

2.3 Storage Motors must be stored as follows:

Important: Motors may otherwise be damaged.

3.1.1 Motor type designation

1 Demag Cranes & Components GmbH Made in Germany

1 Demag Made in Germany

1 Demag Cranes & Components GmbH EN 60034-1

4 183 kg Fl: 50 Hz cos ϕ : 0,84

1 Manufacturer, country of origin, regulation

9 Model, motor weight, inertia factor

B 003 DC brake B007 - B680 DC brakes

1 Brake end cap 6 Electro-magnet 11 Distance spring

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

Connecting pin threads in the terminal box

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

5.1 Requirements Before the motor is put into service:

5.2 Check when Check that:

6.2 Maintenance schedule

Options: • Sealing (covering tape), for brake sizes B003 - B680

Notes for B003 brakes:

Note for B007 - B680 brakes:

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

Brake size B 003 B 007 B 020 B 050 B 140 B 280 B 680

Motor Brake work WN until readjustment in Ws

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

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

includes the assembly instructions.

B 003 260 960 33 – – – – – – 260 962 33

Removing the fan cover and fan

Fitting the fan cover and fan

Checking the remaining thickness of the brake disk

Brake size B003 B007 B020 B050 B140 B280 B680

Remaining thickness b min. 3,5 5 6 7 8,5 10 11

Checking and adjusting the brake air gap

Magnet assembly (9)

Brake disk (3)

Friction plate (14)

End cap (6)

Brake air gap s1min = 0,30 mm - s1max= 1,0 mm (ZBA)