Schunk Bahn- und Industrietechnik GmbH

KM01: Manual and installation guide

Carbon brush wear monitoring device KM01

Brief description
The KM01 is an instrument for permanent, fail-safe monitoring of the wear status of Schunk carbon
brushes with wear detection wire. The device uses two monitoring circuits which enable it to
independently supervise 2 sets of carbon brushes connected to different potentials (e.g. the two
poles of a motor).
Carbon brushes to be monitored need to be equipped with a wire which is insulated against the
potential of the carbon brush. Shortly before the brush reaches its wear limit, this wire is uncovered
and the insulation removed by the rotating slip ring. This connects the wire to the potential of the
carbon brush which is detected by the KM01. Thereby, the device switches to an error state which is
indicated by an LED on the front panel and the switching of a relay. The device can only be reset to
the default state by replacing the worn down carbon brushes, connecting all wires properly and
pressing the RESET-button.

Detailed functionality
The device is connected to the 230V/50Hz grid with terminals N/2 and L1/. As there is no ON/OFF-
switch, the KM01 automatically regains its full functionality after a power outage.
On the front of the device, there are 12 screw terminals on top and bottom, two status LEDs (power
& alarm) and two buttons (Test & Reset).
The green LED power indicates the sufficient power supply and operational availability of the device.
In case the LED is not on or flickering, you should recheck the connection of the device to the grid. A
permanent, failure-free monitoring of the carbon brushes can only be ensured with a continuous
power supply.
The red LED alarm indicates the error state. In combination with the output relay, it signals the
shorting of one of the monitoring circuits. In this case, the user should be aware of the critical wear
status of the connected carbon brushes. The replacement of the brushes is necessary in order to
avoid damage on the brush holders and the slip ring.
If the device reaches the error state, the output relay switches. In default state, there is a voltage of
230 V between terminals 12 and 13. In the error state, there is voltage between terminals 13 and 14.
The output relay allows the user to connect a separate signaling device or monitoring interface (e.g.
speaker or lamp).

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KM01: Manual and installation guide

The button test allows the user to test the functionality of the alarm-LED
and the signaling devices connected to the relay. The test mode is
activated by pressing the button once, and deactivated by pressing it
again. In case of correct installation, the red LED and further signaling
devices connected to the relay will indicate the critical wear status after
pressing the test button once.
The button reset is to reset the device after the replacement of carbon
brushes. Once switched to the error state, the device will only switch
back to default after the installation of new brushes and pressing the
reset button. By pressing the reset button, the device manually checks
the status of the two monitoring circuits and switches back when none
of the circuits is closed.

Fig. 1: Front panel

Installation
Connecting carbon brushes
The first monitoring circuit is set between terminals A/6 and A1/S1; the second circuit between B1/2
and B/7.
As the wiring diagram on the side of the device depicts, the wear detection wires of the carbon
brushes are connected to the terminals A/6 and B/7. The terminals A1/S1 and B1/S2 are connected
to carbon brush potential, i.e. the bus bar that all brushed are connected to.. It is important to check
that the two screw terminals beginning with the letter “A” (same is valid for the two terminals
beginning with letter “B”) belong to one circuit and therefore must be connected to the wear
detection wire and the according carbon brush. Mix up of the terminals of both monitoring circuits
will cause device failure or damage!
Each circuit allows the user to monitor several carbon brushes in parallel interconnection. The device
will switch to error mode once the first brush within series connection will reach its wear limit.
The reset-button needs to be pressed after powering up the device for the first time and after every
replacement of carbon brushes.
Mounting
The KM01 is designed for DIN rail mount. Due to its compact design, it can be installed in a switch
cabinet. The IP40 protection class allows the user to install the device near the monitored machine, if
desired.
Please check all cables for strain relief at first installation to ensure highest reliability of the device.

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KM01: Manual and installation guide

Application
The monitoring device KM01 is applicable for monitoring circuits that are on the motor’s potential as
well as for potential-free circuits.
The high dielectric strength of the transformer and the air gaps and leakage paths allow to monitor
both poles of an electric DC machine (up to a specific voltage of the engine) with one device. The
KM01 is applicable for AC machines as well.

Technical specifications
Supply voltage 230 V AC +10%/-15%, 50Hz
Voltage of output-relay 230 V AC / 8A
Output voltage of monitoring circuit 24 V AC
Short-circuit current of monitoring circuit 250 mA AC, continuous current resistant
Dielectric strength of
Primary winding to secondary winding 4 kV
Secondary winding to secondary winding 3kV
Primary- and secondary winding to core 2kV
Ambient temperature -10°C to +50°C // 14°F to 122°F
Casing protection class IP 40
Mounting for DIN rail (EN 50 022-35)

Exemplary wiring

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KM01: Manual and installation guide

Appendix: Drawing

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