Description Brake motorsKB, SB brake motors FG microspeed units 41409844.eps 0299 EN 203 255 44 714 IS 911 Manufacturer Demag Cranes & Components GmbH Drives P.O. Box 67 · D-58286 Wetter Telephone (+49/2335) 92-0 · Telefax (+49/2335) 927676 E-mail: [email protected] www.drives.demagcranes.com Further literature Data • Dimensions Brake motors KBA, KBL squirrel-cage motors 400 V Data • Dimensions Brake motors KBV, KBF travel motors 400 V SBA slip-ring motors 400 V KBZ, KBS, SBS torque motors 400 V Squirrel-cage rotor brake motors KDF/KMF/KBV/KBF for travel applications Data FG microspeed units Dimensions FG microspeed units 201 620 84 714 IS 911 201 619 84 714 IS 911 202 549 44 200 185 84 200 190 84 203 250 44 714 IS 911 714 IS 911 714 IS 911 714 IS 980 2 Geared motors, catalogue with price code 203255k1.p65/0299 Contents 1 2 2.1 2.2 2.2.1 2.2.2 2.2.3 2.3 2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 2.3.6 2.3.7 2.3.8 2.3.9 2.3.10 2.3.11 2.3.12 2.3.13 2.3.14 2.3.15 2.3.16 2.3.17 2.3.18 2.3.19 2.3.20 2.3.21 2.3.22 2.4 2.4.1 2.4.2 2.4.3 2.4.4 2.4.5 2.4.6 2.4.7 2.4.8 2.4.9 2.4.10 2.4.11 2.4.12 2.4.13 2.4.14 2.5 2.5.1 2.5.2 2.5.3 2.5.4 2.5.5 2.5.6 2.5.7 2.6 2.6.1 2.6.2 Programme Brake motors Brief description, application examples General information Size symbols Standards and regulations Units Electrical characteristics Insulation class Duty-type rating Starting influence on temperature rise Rated output Standard voltage Voltage tolerance Voltage limits for specification Voltage and frequency commutability Connection Rotor-connection of SB slip-ring motors Maximum speeds of SBA slip-ring motors Converting motor data for other voltages and frequencies Starting torque, starting current, no-load current Pole-changing squirrel-cage motors Pole-changing slip-ring motors Rotor layout of pole-changing slip-ring motors Starting frequency KBF travel motor Torque motor with KBZ, KBS squirrel-cage rotor, SBS slip-ring rotor KBL brake motor KBV travel motor Varistors Mechanical characteristics Enclosure Cooling Ambient conditions Mounting Bearings Axial displacement, coupling Direction of axial displacement when braking Balancing Shaft extension Terminal box Housing Enamel KBL brake motor, KBZ torque motor KBV travel motor Brake Brake disc Brake ring (non-asbestos) Life of brake lining Brake torque To reduce brake torque To cancel brake action Brake springs Additional equipment Additional mechanical equipment Additional electrical equipment 5 6 6 9 9 10 10 11 11 11 11 11 11 11 12 12 12 12 13 13 14 14 14 14 15 16 16 16 16 17 18 18 19 19 20 21 21 21 21 21 21 22 22 22 22 22 22 22 23 23 23 23 24 24 24 25 203255k1.p65/0299 3 2.7 2.7.1 2.7.2 2.7.3 2.7.4 2.7.5 2.7.6 2.7.7 2.7.8 2.7.9 2.7.10 2.7.11 2.7.12 2.7.13 2.7.14 2.7.15 2.7.16 2.7.17 2.7.18 2.8 2.8.1 2.8.2 2.9 2.10 2.11 2.11.1 2.11.2 2.12 3 3.1 3.1.1 3.1.2 3.2 3.2.1 3.2.2 3.3 3.3.1 3.3.2 3.3.3 3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.5 3.5.1 3.5.2 3.5.3 3.5.4 3.5.5 3.6 3.7 3.8 3.8.1 3.8.2 3.8.3 3.8.4 3.8.5 3.8.6 Definitions kW required by driven machine Power input Power output Rated motor power Starting current (IA) Rated torque (MN) Starting torque (MA) Pull-up torque (MS) Breakdown torque (MK) Brake torque (MB) Duty types Relative duty factor (DF) Factor of inertia External moments of inertia Starting time Braking time Starting revolutions Braking revolutions Motor selection Ambient temperature and altitude Determining the permissible starting frequency Noise Measurement of temperature rise of windings Winding protection PTC thermistors Temperature detectors Anti-condensation heater Microspeed units Brief description, application examples Advantages Application examples General information Size symbols (Short form) Specifications, standards Electrical characteristics Motor data Connection Stepless micro motor operation Mechanical characteristics Mounting Direction of rotation Terminal box Separate fan Further details Brake Brake disc Brake torque reduction To cancel brake action Additional equipment Clutch Intermediate gear, arrangement Geared microspeed units Selecting a microspeed unit Symbols Selection from data list Further possibilities for selection Selection without microspeed unit data lists Variation of data Determination of exact speeds 26 26 26 26 26 26 26 27 27 27 27 27 28 28 29 29 29 29 29 30 30 31 33 33 34 34 34 35 37 37 38 38 38 38 38 38 38 38 39 39 39 39 39 39 39 40 40 40 40 40 40 40 41 42 42 43 43 44 44 44 4 203255k1.p65/0299 90 KB 71 .225 Microspeed motors KB 71 .100 ( 112) 112 .112 KB 71 .140 ( 160) 160 . A 140 B .1 Programme Brake motors Squirrel-cage motor Squirrel-cage motors Range KBL KBA Sizes 71 A 71 A 80 A 90 A 100 A 112 B . A 125 B .225 100 ( 112) 112 .90 KB 71 .140 ( 160) 160 .140 203255k1.140 KB 71 .p65/0299 5 .112 KB 71 . A 71 B 71 B 80 B 90 B 100 B 112 B 125 B 140 B 160 B 180 B 200 B 225 B Travel motors with squirrel-cage rotor KBV KBF 71 A 71 A 80 A 90 A 100 A 112 A 125 A 140 A 71 B 71 B Torque motors with squirrel-cage rotor KBZ KBS 71 B 80 B 90 B 100 B 112 B 125 B 140 B Slip-ring motors SBA 100 B 112 B 125 B 140 B 160 B 180 B 200 B 225 B Torque motors with slip-ring rotor SBS 100 B 112 B 125 B 140 B 160 B 180 B 200 B 225 B Microspeed units Main motors KBA squirrel-cage motors Microspeed gears F G 06 F G 08 F G 10 SBA slip-ring motors F G 06 F G 08 F G 10 Main motors 71 . KBF ranges 1 2 3 4 5 6 7 8 6 Shaft Motor end cap. The Demag motor has proved a reliable machine in all branches of industry.p65/0299 . 1 Arrangement with conical brake disc with flat brake disc 1 2 3 4 5 6 7 8 9 10 11 12 14 13 15 16 17 41259744. due to the conical air gap.2 Brake motors 2. When de-energized or in case of mains failure the field collapses and the brake spring displaces the rotor.1 Brief description. Characteristic of the Demag motor is the cone shell shaped air gap. incorporating fan (shown: light conical brake disc) 11 Conical brake ring 12 Brake cap 13 Tensioning nut 14 Tensioning screws 15 Retaining ring 16 Flat brake disc. This axial displacement.e. At rest the motor is braked. overcomes the force of the brake spring and draws the rotor into the stator. (shown: heavy flat brake disc) 17 Flat brake ring 203255k1. drive side Spring ring Pressure ring Brake spring Adaptor rings Stator Rotor 9 Motor end cap. releases the brake and allows the motor to accelerate up to full speed like any normal motor.eps Demag brake motor with squirrel-cage rotor KBA. It is mainly used for drives requiring: • • • • • • • braking of loads and overhauling torques braking of inertia shorter overruns improved indexing precision braking in emergencies to prevent accidents braking in case of trouble to avoid rejects a constant holding torque at standstill Fig. which is limited by the bearings. It can be supplied as squirrel-cage motor or alternatively as a slip-ring motor. pushing it with the brake ring fitted on the brake disc against the braking surface. brake side 10 Brake disc. i. application examples The Demag motor is a combination of an electric motor and a spring-loaded brake operating on the sliding rotor principle. When energized an axial component of the magnetic field. the conical rotor and stator bore. p65/0299 41415444.Fig.eps s Front view of a Demag KBA brake motor t Sectional view of a Demag brake motor Fig. 2 41239944.eps 7 . 3 203255k1. milling. and planing machines Bending machines Multi-spindle tapping machines Roll adjusting drives • Log band saws Ram adjustment of presses Valve control of hydraulic pumps Spring testing machines • Dividing machines Shoe making machines Embroidering machines Racking machines • Printing machines Bottle cleaning machines Bottling machines Packaging machines Power looms Coiling machines Kneading machines Wire drawing equipment Brush manufacturing machines Paper cutting machines Veneer cutting machines Wood working machines Rapid braking of masses to eliminate time-consuming overruns Repeated braking where precise angular position is critical Emergency braking to prevent accidents or damage to material 8 203255k1. carriage.p65/0299 .Application examples Braking of loads coupled direct to the motor shaft Hoist units Winches Stackers Small capacity goods lifts Inclined hoists • Bucket elevators Elevators • Lifting platforms Inclined belt conveyors Hinged shutters • Tipplers Fire doors of industrial furnaces Plate shears Folding machines Drives of lathe. and tool carrier drives of milling. and grinding spindles Balancing machines Drilling machines Pump drives Viewing and control machinery Bucket scales Shakers and vibrators Small centrifuges Long travel units • Slewing gears Sliding doors Table. grinding. 4 112 B 4 A 203255k1.2.Z Type.2.V S.L F.2 General information 2.1 Size symbols K S B A.p65/0299 9 . range Squirrel-cage motors Slip-ring motors Brake General brake motors Travel motors Torque motors Frame size Shaft height Stator core length Number of poles Special designs KBA Fig. 2. For the conversions see the data lists. measurements. IM B8. IM V5.2 see special output tables Others • EN 60034 part 12: Starting characteristics of AC squirrel-cage motors • DIN 748 part 3: Cylindrical shaft ends for electric machinery • DIN 42925 Entry fittings in terminal boxes for AC motors 2. in particular with: • EN 60034 (IEC 34) Rotating electrical machines • EN 60034-1 (IEC 34-1) Rating and performance • EN 60034-5 (IEC 34-5) IP types of enclosure (IP code) • EN 60034-7 (IEC 34-7) Types of construction and mounting arrangements (IM code) IM B3.3 Units Units defined by the “Law on units of measurement” according to the International System of Units (SI) have been used. IM V1. IM B7. IM V18. 203255k1. IM V6.p65/0299 10 . IM V3. IM B14. IM B6. • CSA.2.2.2 Standards and regulations Demag AC motors with and without brake comply with all relevant standards and regulations. IM V19 mounting arrangements implemented • EN 60034-8 (IEC 34-8) Terminal markings and direction of rotation • EN 60034-9 (IEC 34-9) Noise limits • EN 60034-14 (IEC 34-14) Mechanical vibrations. Specification C 22. evaluation and limits of vibration severity • EN 60034-18-1 (IEC 34-18-1) Functional assessment of insulation systems • DIN IEC 38 IEC standard voltages • EN 60529 IP enclosures for electrical equipment • Tolerance N for concentricity and shaft extension run-out to DIN 42955 • Most IEC dimensions IEC 72-1 and IEC 72-2 • Terminal markings to DIN EN 60 445. IM B5. 140 Three-phase AC 230/400 V D/Y 290/500 V D/Y squirrel-cage motor slip-ring motor 2. 4 poles slip-ring motor 6 poles Motor circuit diagram 020 323 84 025 101 84 025 102 84 For sizes 160 . 2. According to EN 60034-18-1 (IEC 34-18-1).3.2. 2. +6/-10 % of rated voltage 203255k1.3 Electrical characteristics 2.7.3.5 Standard voltage For sizes 71 . Special insulation is available against surcharge.60 % .FI 2 (see 2.3 Starting influence on temperature rise In case of intermittent duty S 4 the required starts per hour c/h (cycles per hour) and the factor of inertia FI should always be mentioned e.p65/0299 DIN IEC 38 11 .600 c/h .2 Duty-type rating There are two different winding layouts. 40 °C max. The motors are normally tropicalized for operation in hot and dry surroundings.8.g.4 Rated output Frequency Cooling agent temperature Altitude 50 Hz max.13) 2.3.: S 4 . thus providing corresponding temperature protection.3. It comprises: • Moisture-proof insulation (protection against high atmospheric humidity also in the case of temperature variation) and/or • Acid-proof insulation (protection against acid gases and vapours).6 Voltage tolerance ± 5 % of rated voltage In the case of this voltage tolerance the temperature rise limit of 105 K can be exceeded by 10 K in continuous duty.225 031 248 84 031 804 84 031 449 84 2.225 Three-phase AC 400 V D 500 V D squirrel-cage motor slip-ring motor size 160 slip-ring motor sizes 180 . 1000 m above sea level In the case of different conditions see 2. in the data lists they have been separated by a line: • Continuous duty • Intermittent duty S 1 (100 % CDF) and intermittent duty S 3 – 60 % S 3 with 40.3.3.1 Insulation class Motors are supplied as standard with insulation material for thermal class F. the temperature for thermal class F is 155 ºC. the temperature rise limit of the winding is 105 K and the maximum cooling agent temperature is 40 ºC. According to EN 60034-1 (IEC 34-1). 25 and 15 % CDF 2. 60 % of list values. ratio 1: 3 : 2 : 2 ⋅ 3 Motor circuit diagram 020 337 84 e. Links of three-phase motors for connection in Y or D are lined up on the bottom left terminal.3. Wrong: 220 V D Correct: 220 V D for Y/D start The brake torque is reduced to approx. 30 % and starting current approx. sizes 160 – 225 • for pole-changing motors Connection of the three-phase rotors • up to size 160 (star point not brought out) K Fig.9 Connection On delivery Demag sliding rotor motors are unconnected.3. Starting torque of Y/D motors is approx. since in this case a weaker brake spring has to be fitted. ratio 1:2 3 voltages 4 voltages.eps • Sizes 180 – 225: Rotor in D connection. min.8 Voltage and frequency commutability Terminals 2 voltages.g.g.10 Rotor-connection of SB slip-ring motors Three-phase for • 2 and 4-pole motors • for 6-pole motors. 12 203255k1. min.g. If Y/D start is required.3.7 Maximum voltage Minimum voltage Three-phase AC: up to 600 V (in Y connection) at no extra price above 600 to 750 V against extra price min. 42 V 73 V 110 V 220 V (in D connection) for frame sizes 71 and 80 (in D connection) for frame sizes 90 and 100 (in D connection) for frame sizes 112 – 140 (in D connection) for frame sizes 160 – 225 2. this must be stated in the order.p65/0299 . 5 L M 412 598 44. min. 1/3 of its listed value. 2.2. The rotor return time increases to 4 – 5 times its value. 230/400/460 V DD/YY/D 6 12 020 341 84 e.3. 230/460 V YY/Y e. 115/200/230/400 V DD/YY/D/Y 12 D/YY 12 020 341 84 020 325 84 2 frequencies 50/60 Hz 2. 112 125.11 Maximum speeds of SBA slip-ring motors The maximum permissible speeds for lifting operation are (irrespective of the number of poles): Motor SBA Size 100. 13 .p65/0299 Description New power Rated power at 400 V. 6 i.17. 50 Hz New frequency New current Rated current at 400 V. The following equations can be used for conversion to a different voltage and/or frequency for appropriately modified windings.Two-phase for 6-pole motors Sizes 100 – 140 Connection of the two-phase rotor i K u ph u Fig.12 Converting motor data for other voltages and frequencies Motor data are given for a voltage of 400 V and a frequency of 50 Hz. 2 Q u ph L i u uph i = (phase-to-phase) rotor voltage = uph ⋅ 2 = phase rotor voltage = rated rotor current i ⋅ 2 = rated rotor current of the middle phase 412 599 44.3. 140 160 .eps 2. 50 Hz New voltage New speed Synchronous speed at 50 Hz Rated speed at 50 Hz nN Starting frequency z0 : see section 2. Power: Px = PN ⋅ f x 50 Hz Speed: n x = n sy 50 Hz ⋅ fx − n sy 50 Hz − n N 50 Hz ( ) Currents: with nsy 50 Hz: 2 poles = 3000 min-1 4 poles = 1500 min-1 6 poles = 1000 min-1 8 poles = 750 min-1 12 poles= 500 min-1 Unit kW kW Hz A A V min -1 min -1 min -1 fx 400 V I x = IN ⋅ ⋅ 50 Hz U x Abbreviation Px PN fx Ix IN Ux nx n sy50 Hz 203255k1.225 Maximum speed 3600 rpm 1800 rpm 1200 rpm Note only for 50 Hz for 50 and 60 Hz for 50 and 60 Hz 2.3.3. p65/0299 Starting resistors control acceleration and electrical deceleration which both take place while the 2-pole winding is energized. ∆ / Y (16/4/2 poles) two windings Y/D/YY Motor circuit diagram 6 020 328 84 6 12 020 332 84 020 347 84 • 750/1500 rpm 6 020 328 84 • 750/3000 rpm 500/1500 rpm 500/3000 rpm 375/3000 rpm 375/1500 rpm 6 12 020 332 84 020 347 84 • 375/1500/ 3000 rpm 9 020 334 84 2. starting current and no-load current values irrespective of duty factor and output.) Switching over to the slower speed must not take place before this speed has been reached during acceleration or deceleration. no-load current The two winding designs (see section 2.3. .16 Rotor layout of pole-changing slip-ring motors • 1500/3000 rpm Rotor winding D/YY 4 poles: Winding short-circuited 2 poles: Slip-rings allow control of the starting and braking process through rotor resistors Rotor winding Y/Y 8 poles: Winding short-circuited 2 poles: Slip-rings allow control of the starting and braking process through rotor resistors • 750/3000 rpm 14 203255k1. starting current.2 “Duty-type rating”) have different specific starting torques.2. KBA: single winding in Dahlander connection D/YY (8/2 poles) (12/4 poles) (12/2 poles) (16/2 poles) (16/4 poles) two separate windings for one voltage only for voltage ratio 1: 3 ∆ / Y.3.14 Pole-changing squirrel-cage motors Terminals • 1500/3000 rpm (4/2 poles) KBL. A time relay should be provided for monitoring purposes.3.15 Pole-changing slip-ring motors • 1500/3000 rpm (4/2 poles) • 750/3000 rpm (8/2 poles) circuit diagram 020 356 84 circuit diagram 020 355 84 two separate stator windings 2. Tolerance to EN 60034-1 (IEC 34-1) Starting torque: Starting current: – 15 % to + 25 % of the listed value + 20 % of the listed value 2. KBA: single winding in Dahlander connection D/YY KBV. ∆ / Y (8/4 poles) KBL.3. KBF: two separate windings Y/Y for one voltage only for voltage ratio 1: 3 ∆ / Y.3.13 Starting torque. (An acceleration with the 4 or 8-pole short-circuit winding being energized is impossible. To each winding design a maximum brake torque is assigned. if exact data of the application are furnished.17 Starting frequency The no-load starting frequency z0 listed in the tables against the various duty factors indicate the permissible starts per hour c/h without load and without external moment of inertia with a light brake disc.p65/0299 15 . For frequencies other than 50 Hz. In the case of pole-changing motors the listed no-load starting frequency per hour refer to operation at the given speed only.3. Combinations of starting frequency at all possible speeds can only be checked.2. value z0 is recalculated according to the following equation: z0 X = z0 ⋅ 50 2 Hz 2 fx 2 Abbreviation z0 fX z0X Description No-load starting frequency from list at 50 Hz New frequency other than 50 Hz No-load starting frequency for new frequency Unit h-1 Hz h-1 203255k1. circuit diagram 020 323 84 Special layout: D/YY with 12 terminals.18 KBF travel motor Brake motor with squirrel-cage rotor with an especially “smooth” torque/speed curve for travel and high inertia drives. Torque motor with squirrel-cage rotor If the motor is normally connected to the supply in star.4. it should be switched off via a time relay during longer rest intervals with consequent mechanical braking.3. Separate fan To increase the torques the motors can be fitted with a separate fan.3. 2. This is not applicable for externally cooled torque motors KBS . part of the rotor resistance can be shortcircuited for up to 2 minutes in 60 minutes. even if the motor to be cooled is rated for short-time duty S3. The latter must always be rated for continuous duty S1.13 2.21 KBV travel motor See 2.3. 6 terminals..4.p65/0299 ... Thus motor and brake are designed to come under the same type of enclosure. In the case of a failure of the separate fan the motor protection (see 2. KBS slip-ring rotor SBS Torque motors are used whenever a constant torque is required either at standstill or at low speed (referred to 50 Hz) Squirrel-cage motor KBZ 8 poles KBS 12 poles Slip-ring motor SBS 4 poles operation range – 750 to + 750 rpm operation range – 500 to + 500 rpm operation range – 600 to + 1500 rpm The operation range of torque motors with slip-ring rotor is valid for motors with a fixed rotor resistor. F. circuit diagram 020 327 84 D connection: stalled torque at S1 = 100 % of value listed for S1 YY connection: stalled torque at S3 – 60 % = 130 % of value listed for S1 Torque motor with slip-ring rotor To obtain an initial break-away torque. 2.11) or an air-flow monitor provide for protection against overheating.2. The brake of torque motors is totally enclosed up to size 140. To relieve a torque motor rated for S1 from thermal stress during heavy duty. The stalled torque can be reduced by increasing the rotor resistance.20 KBL brake motor See 2.3.14 16 203255k1. an initial break-away torque of 3 times the stalled torque can be obtained by first connecting the motor in delta during up to one minute in 60 minutes (increased break-away torque). F and SBS .19 Torque motor with squirrel-cage rotor KBZ.. With a variable resistor the operation range is extended to –1000 rpm. only the highpole winding is protected by means of varistors. varistors can be fitted. at extra cost. This affects the following brake and torque motors in the range up to 500 V operating voltage: Size KBL KBA KBA KBA 71 A .3. The set of varistors is accommodated in the motor terminal box. B 80 A 90 A KBF 100 A KBF 112 A 3 varistors are required for each motor. B 71 A . All motors with operating voltages above 500 V have phase insulators and do not require this special protection either. In order to protect the brake motors. B 71 A .22 Varistors Due to modern. B KBA 112 B KBA 125 B KBZ KBS KBV KBF KBF KBF 71 B 80-112 B 71 A . B 80 A . For SBA and SBS slip-ring motors no protection is provided because no excessive switching peaks are expected.p65/0299 17 . Notwithstanding the above. the combination of high leakage inductance with poor mains conditions can result in high voltage peaks in the windings of high-pole motors. if required.2. B 90 A . extremely fast contactors. In the case of pole-changing brake motors with two separate windings. They are combined to form a set and have flexible connection leads. the sizes concerned are protected by fitting varistors (voltagedependent resistors) as a function of their number of poles. B 6 6 – – – – – – – – – – – – – 8 8 8 – – – – 8 – – – – – – – 12 12 12 – – – – – 12 – – – – – – 8/4 8/4 8/4 – – – – – – – – – – – – Number of poles 6/2 6/2 – – – – – – – – – – – – – 8/2 8/2 8/2 – – – – – – 8/2 8/2 8/2 – – – – – 12/2 12/2 12/2 12/2 – – – – – 12/2 12/2 12/2 12/2 – – 12/4 12/4 12/4 12/4 – – – – – 12/4 12/4 12/4 12/4 – – – 16/2 16/2 16/2 16/2 – – – – – – – – – – – – 16/4 16/4 16/4 – – – – – – – – KBA 100 A. 203255k1. which are rated for high switching frequencies. No protection is required for the lowpole winding. 18 203255k2. with interior mobile parts or with live parts. in this case the enclosure is IP 44. Protection against granular foreign bodies. e. For detailed description of the enclosures and the test conditions see EN 60034-5 (IEC 34-5). On request they can be supplied with open condensation water drain holes. Since condensation water drain holes should always be situated at the lowest point of the motor the mounting arrangement must not be changed at a later date. Protection against jets of water from all directions. When they are closed the enclosure is IP 54. Protection against splashed water from all directions.g. If the motor is installed outdoors for a longer period without being operated it is recommended to order a motor with a protected braking surface to avoid rust formation. Protection against splashed water from all directions. For motors in a vertical position with the shaft showing downwards a canopy can be supplied against extra price. IP 44: Protection against contact with tools etc.2. In these cases the motor should be designed for IP 55 or suitable protecting measures should be taken. it might be possible that enclosure IP 54 is no longer sufficient.g.1 Type of enclosure Motor housing IP 54 standard arrangement IP 55 against extra price Terminal box Brake housing IP 55 standard arrangement IP 20 standard arrangement IP 54 • against extra price (account should be taken of a power reduction which might be necessary) • standard arrangement with KBL. IP 55: Protection against injurious dust deposits. Brief description of the enclosures IP 20: Protection against finger contact with interior mobile parts or with live parts. if the motor is not protected against rain and wind or if the site altitude is very high.4. For occasional water draining screwed water drain holes can be supplied. Outdoor mounting If a motor is operated outdoors under severe operating conditions. installation of a weather protection. IP 54: Protection against injurious dust deposits. otherwise it is IP 44. e. KBV brake motors (no power reduction) IP 55 • for self-cooled torque motors KBS 80 – 140 SBS 100 – 140 Motors designed for enclosure IP 54 do not have condensation water drain holes.4 Mechanical characteristics 2.p65/0299 . 4.Fan-cooled motors installed outdoors The fan is generally supplied in enclosure IP 55.03 0. 100 112.13). 80.4. 125 140. An air intake section can also be fitted to the air intake opening of separate fans. When fitting the fan it should be made sure that the air intake opening of the fan is directed to the side which is protected against wind and rain. 160 180 – 225 Air flow Vmax Increase in static pressure ) pmax Output Nominal current at 400 V 3 AC Weight m3/min Pa kW A kg 3.6 Fan size D 04 D 05 D 060 2. see section 2. 1000 m above sea level For any other conditions.2 Cooling Self-cooling The brake disc is fitted on the motor shaft and serves as fan for surface ventilation (not for KBL. 203255k2. Sizes and technical data Motor Size 71.2 330 0. 2.07 0. The drive motor can also be fitted with a fan cover with a protective canopy for D 06 and D 064 separate fans.5 1.7 5. The required mounting position of the air intake opening has to be specified in the order.3 Ambient conditions Coolant temperature: -20 °C up to +40 °C Installation altitude: max.8. see also operating instructions 201 360 84.0 350 0.0 430 0.17 3.4.4 4.4 5. see 2.4 9.13 0. If this is impossible suitable measures should be taken in order to protect the air intake opening of the separate fan against the entry of water and snow.0 D 03 x x x x 20 730 0.p65/0299 19 . This raises their output and switching frequency. Separate cooling Motors which are to have separate cooling are equipped with a fan attachment.5 10. 90. eps 203255k2.5. The Demag motor is available with one shaft extension only. 7 412 185 44. flange mountings largely to DIN 42677.4. IM B 3 IM B 6 IM B 7 IM B 8 IM B 5 IM V 1 IM V 3 IM V 5 IM B 14 IM V 18 IM V 19 IM V 6 20 Fig.p65/0299 .2. The flange of flange-mounted motors can be unscrewed. Mountings ® Selection from EN 60034-7 (lEC 34-7) In the case of a vertically mounted motor strictly observe instructions given under 2. Foot mountings correspond largely to DIN 42673. The dimensions correspond largely to IEC Publication 72-1.7! For the possible arrangements see the corresponding dimension lists The feet of foot-mounted motors can be unscrewed.4 Mounting Foot mountings and flange mountings according to the table of mountings. 140 160. The bearings are sealed with special shaft seals (seals with sealing lip).5 Bearings 2 roller bearings and 1 axial deep-groove ball bearing. 200.8 2.5 To make sure that the axial displacement will not be hindered the following points should be observed: Gear drive: Coupling: Belt: The pinion should have straight teeth. 2.2.4. 112 125. are housed in the terminal box.4.5 1. When ordering please quote: “Drive end oil-tight”. When flanged motors are mounted on gears or similar machines the drive end bearing is sealed against splash oil from the gearbox by means of a radial shaft sealing ring.6 Axial displacement.5 4. 225 Displacement Iv [mm] lv min 1. Only use flexible couplings allowing an easy axial movement between the hubs of the coupling.0 3.p65/0299 21 . if any. 203255k2. This is not applicable for Demag geared motors.3 lv max 3.7 Direction of axial displacement when braking 2.9 Shaft extension 2. Squirrel-cage motors have 1 terminal box containing 6 or 12 terminals according to the special needs. Variable speed pulleys: Only change speed when motor is running.4. 180. The rotor has been balanced dynamically with a halved key. The Demag motor is constructed with one shaft extension. 2. Slip-ring motors have 1 terminal box for stator and rotor. The initial tension must not hinder the axial displacement of the rotor. Additional terminals for anti-condensation heaters. 80. coupling Axial displacement of the shaft Frame size 71.4. The tapped holes are sealed by means of dummy plugs.4.0 4.4.8 Balancing 2.. temperature sensors etc.10 Terminal box From DE to BE. 90 100. The terminal boxes have a connection terminal for the protective conductor and tapped holes for glands.0 2. 5.4. Other enamel types and special protective enamels are possible against extra price.6 not at all. 2. Bearings: 2 deep-groove ball bearings. Therefore 2.5.11 Housing Size 71 – 140 : Die-cast aluminium 160 – 225 : Grey cast iron 2. Hence longer starting time and considerably longer braking time. KBZ torque motor Brake motor without fan.5. longer starting and braking times. J approximately 2 to 3 times that of light conical brake disc.4. 2. i.4.2 and 2. fitted with integrated conical brake which can be adjusted only once. 2.4.2 Brake ring (non-asbestos) Consists of brake lining bonded to a rubber ring to absorb shocks during braking.5.5 apply only in part to the KBV motor.5 Brake 2.5. (Standard arrangement for KBF travel motor) • Light flat brake disc with low moment of inertia J (sizes 71 – 100 only) Brake torque approximately 25 % of brake torque of conical brake disc.1 and 2. In the case of horizontal mountings the brake discs can be replaced without modification of the brake springs. 2. 2.4.2 and 2.1 Brake disc The following brake discs are available: • Standard (for KBA. 2.5. SBS motors no special indication is required in the order): Light conical brake disc with low moment of inertia J for a high number of starts per hour. Additional equipment cannot be fitted. • Heavy flat brake disc with higher moment of inertia J. Standard brake rings: • Form A (wide): • Form B (narrow): for 4 and 6-pole KBA brake motors for all other brake motors 22 203255k2. KBS.13 KBL brake motor.12 Enamel Blue anti-corrosion enamel type RAL 5009. Therefore 2. Additional equipment cannot be fitted. fitted with integrated light conical brake which can be adjusted only once.5. J approximately 2 to 3 times that of light flat brake disc. 2.p65/0299 . Brake torque approximately 25 % of brake torque of conical brake disc. SBA.6 not at all. 2. Hence longer braking time.5.5.4.5.2. The moments of inertia of light or heavy conical and flat brake disc are practically equal. • Heavy conical brake disc with a higher moment of inertia J. Hence smooth starting and braking. Bearings: 2 deep-groove ball bearings.1 and 2.4.14 KBV travel motor Travel motor with heavy fan.e.4.5 apply only in part to the KBL and KBZ motors. KBF travel motors has been designed for the brake torque which is most favourable for the travel drive.5. in addition the highest possible brake torque is indicated in the data lists.5. F torque motors: 40 % of the rated brake torque 60 % of the rated brake torque 40 % of the rated brake torque 60 % of the rated brake torque down to standstill 0 % (brake spring must not be weakened) • Use brake torque setter attachment type BEG Infinitely variable reduction by approximately 1/3 to 2/3 of the values listed for conical and flat brake discs.3 Life of brake lining Determined by • • • • • frame size motor speed torques to be braked moments of inertia starts per hour. brake torque approximately 25 % of value listed for conical brake disc with same brake spring • Remove adaptor washers from behind brake spring. 2. KBL.p65/0299 • In the case of slip-ring motors: energize stator inserting a high external resistance into the rotor circuit. 2. Motors for 60 Hz have the same brake torques as motors for 50 Hz..6 To cancel brake action • • • • Use manual brake release attachment Use load lowering attachment Use load lowering device Use electric brake release attachment Use load lowering equipment Use brake release device type HBLG type LAG type LAE type EBLG type LAF type BLE for motor assignment see 2. SBS motors has been designed for the highest possible brake torque (list torque).1 203255k2. 2..4 Brake torque The brake torque in the data lists refers to both the static brake torque (static friction) and dynamic brake torque. The brake of KBA.5. SBA. brake torque reduction approximately 5–10 % per washer • Use weaker brake spring The maximum possible brake torque reduction is for 4 and 6-pole KBA brake motors: for 4 and 6-pole KBA brake motors on Dematic inverters: for 4 and 6-pole SBA brake motors: for KB and SB brake motors with other pole numbers: for SBS torque motors: for SBS . In case this brake torque (or another intermediate value) is required this should be stated in the order.5 To reduce brake torque • Use a flat brake disc. 23 .5. KBS.2. The brake of KBV. KBZ.6. 112 KB 125-225 SB 125-225 Electro-magnetic device of EBLG holds brake in released position after the motor is switched off. therefore please ask for confirmation when a vertical or an inclined position is required. e. 24 203255k2. For wiring diagrams see operating instructions EBLG. 110. The brake springs can be selected from special tables for brake springs. and a weaker spring is fitted with the output shaft upwards! In some cases the vertical position is impossible.g.6 Additional equipment 2.g. until brake is released. Allows gradual lowering of load. Thus 65 to 100 % of the listed brake torque can be obtained. Rotor can be turned by means of shaft extension.2) In the case of a motor mounted in a vertical position a different brake spring is fitted to compensate for the weight of the rotor. 50 Hz : 24.2. 127. Coil duty factor max. S 3 –10 %.1 Additional mechanical equipmenet Manual brake release attachment HBLG 2 for HBLG 3 for KB 125-225 SB 125-225 KB 71-112 SB 100. Brake remains released until motor is again energized. 220. 42.5. hoist units! Further manual brake release attachments on request: HBLG HBLG HBLG HBLG 4 5 6 7 HBLG 8 HBLG 9 HBLG 10 HBLG 11 Load lowering attachment LAG 2 for LAG 3 for KB 125-225 SB 125-225 KB 71-112 SB 100. 290 Volt. Not suitable for overhauling loads. 2. Available coil voltages for DC: 24 V and 48 V. A special circuit layout avoiding above is available. to 2. Brake torque setter attachment BEG 2 for BEG 3 for KB 125-225 SB 125-225 KB 71-112 SB 100. rotor can be turned with hand wheel or crank. Not permissible for microspeed motors driving hoist units! Electric brake release attachment EBLG 1 for EBLG 2 for KB 71-112 SB 100. brake can be released with brake lever. Input 220 VA operating.9) • Stator-resistance starting circuit (e. A stronger spring is fitted when the motor is mounted with output shaft downwards. When released. 112 Setting of brake torque by means of an additional spring adjustable from outside. the brake disc.6. plus possibly the weight of a pulley or coupling half. but the motor starting current exceeds the listed value. Normally the rotor receives a short rotary impulse when the EBLG is energized.6. Brake release push button should be actuated for at least 0.p65/0299 . 112 Brake can be released by turning brake lever.3.5 sec. tolerance +5 % to -10 %.7 Brake springs Compared with standard arrangement the motor is equipped with a weaker brake spring in the following cases: • Y/D starting (see 2. by means of appliance KSAG acc. 112 With power off. Available coil voltages for AC. absolute position encoder Canopy for brake BLE 1 LAE 1 LAE 2 BLK BVK 2. 214 029 44 203255k2. Two sensors trace a multi-pole magnet ring fixed on the rotor shaft during rotor rotation.6. monitoring and switching contacts. 203 091 44 Operating instructions EG integrated pulse generator system Ident.p65/0299 25 . For further details see leaflet Description • Data • Dimensions • Operating instructions Dematik KSAG smooth starting unit Ident. no. no.Further devices (on request) Brake release device Load lowering device Brake release checking device Brake wear checking device Separate fan Tachogenerator.2 Additional electric equipment EG integrated pulse generator The Demag EG integrated pulse generator is fitted in the area of the brake of the Demag motor. no. 214 033 44 Dematik KSAG smooth starting unit This electronic device has been designed for the reduction of the run-up torque of three-phase squirrel-cage motors. For further details see leaflets Description • Data • Dimensions EG integrated pulse generator system Ident. The corresponding electronic evaluator unit is connected to the generator via connectors in the terminal box of the motor. Depending upon the specific application and the evaluator unit the generated signals can be used together with the MSEG unit for information. no. 214 053 44 Dematik MSEG motor control unit The MSEG unit reduces the starting torque of a pole-changing squirrel-cage motor in both speeds. For further details see leaflet Description • Data • Dimensions • Operating instructions Dematik MSEG motor control units Ident. Furthermore electric braking from high speed to low speed is adjustable with this unit. 5 Starting current (lA) The starting current of a motor is the maximum current it will take from the line at rest with rated voltage applied at rated frequency.7.7. frictional force) linear speed efficiency of the driven machine power input rated voltage current in kW in Nm in rpm in N in m/s F v ha 2.7.7 Definitions 2.6 Full-load torque (MN) MN = 9550 ⋅ PN nN MN PN nN full-load torque rated output rated speed in Nm in kW in rpm M MA MK MS MN nN n MB Fig.eps 203255k2.7.3 Power output P2 = 3 ⋅ U ⋅ I ⋅ cosϕ ⋅ η P2 h power output efficiency of the motor in W 2.2.4 Rated output (in the date lists of the motors indicated as P) PN = 3 ⋅ U ⋅ IN ⋅ cosϕ ⋅ ηN = 3 ⋅ U ⋅ IN ⋅ cosϕ ⋅ ηN 1000 PN IN hN rated output rated current rated efficiency in W in A 2.7.2 Power input P1 = 3 ⋅ U ⋅ I ⋅ cosϕ P1 U I in W in V in A cos j power factor 2.7.p65/0299 . 8 Torque/speed curve 26 41217444.1 kW required by driven machine P= M⋅n 9550 ⋅ ηa P M n or P= F⋅v 1000 ⋅ ηa kW required by driven machine torque required by driven machine speed force (weight. 2. 8 Pull-up torque (MS) 2. Other duty types must be determined on the basis of equivalent loading as a function of time and load.2.7.7. The pull-up torque of a motor is the minimum torque developed by the motor with rated voltage applied at rated frequency during the period of acceleration from rest to the speed at which breakdown torque occurs.7.7. 2. 27 . Decelerating brake torque occurring when the brake ring meets the braking surface.eps t B Time under load tSt Idling time tS Time cycle 203255k2.7. The duty type must be quoted in the order together with the corresponding specification.eps Time tB Time under load 41614144.11 Duty types The most common duty types S1. = tB ⋅ 100% tB + tSt tA tB tS tSt Starting time Time under load Time cycle Idling time = t A + tB ⋅ 100% t A + tB + tSt Cyclic duration factor referring to 10 min. S2. when locked via fan and brake ring.p65/0299 Cyclic duration factor referring to 10 min.eps Periodic intermittent duty S3 Periodic intermittent duty with influence of starting ts tA tB t St S4 ts tB t St Load Load Time 41614244. The breakdown torque of a motor is the maximum torque it will develop with rated voltage applied at rated frequency between pull-up speed and rated speed. 2.7 Starting torque (MA) The starting torque of a motor is the torque it will develop at rest with rated voltage applied at rated frequency.10 Brake torque (MB) Static brake torque Dynamic brake torque Maximum torque which the shaft.eps Time 41614344. Continuous duty tB S1 Short-time duty tB S2 Load Load Time tB Time under load 41299944. can oppose to an outside torque acting on the output shaft. S3 and S4 are described in the diagrams below.9 Breakdown torque (MK) 2. load torque and inertia moment 2. Maximum time cycle 10 minutes. S2 – 30 min. e. e. starts per hour.12 Relative duty factor (DF) Ratio of time under load: time cycle (Time cycle = sum of operating periods and periods of rest).g. DF = Sum of operating periods ⋅ 100 Time cycle in % 2.13 Factor of inertia The factor of inertia FI is the relation between the moment of inertia of all masses referred to the motor shaft and the moment of inertia of the motor (rotor plus brake disc).) Periodic intermittent duty with influence of starting Cyclic duration factor CDF in %. Required information – Time under load Periodic intermittent duty without influence of starting (indexed operation).g. J + JZus FI = Mot JMot Jmot Jzus moment of inertia of motor in kgm2 external moment of inertia referred to motor shaft in kgm2 28 203255k2. S3 – 40 % Cyclic duration factor CDF in % (referring to 10 min.p65/0299 .7.7.Duty types according to EN 60034 (IEC 34-1) Abbreviation S1 S2 S3 S4 Description Continuous duty with 100 % CDF Constant load for short period. 7.7.17 Starting revolutions zA = zA starting revolutions 2. – ML when the load torque is opposed to the brake torque (overhauling loads – lowering).18 Braking revolutions zB = zB tR braking revolutions rotor return time in s These values for tR are between 0.14 External moments of inertia Determination of moment of inertia referred to motor shaft of rotating masses JZus = 2 J1 ⋅ n1 + J2 ⋅ n2 2 + ⋅⋅⋅ JZus n m v n 2 external moment of inertia motor speed weight linear speed in kgm2 in rpm in kg in m/s of masses in linear motion JZus = 91. 2. Exact values on request.2.2 ⋅ m ⋅ v 2 n2 Important for rotating bodies Solid cylinder J = 98 ⋅ ρ ⋅ L ⋅ D4 a J r L moment of inertia specific weight length outside diameter inside diameter in kgm2 in kg/dm3 in m in m in m Hollow cylinder 4 J = 98 ⋅ ρ ⋅ L ⋅ D4 a − Di ( ) Da Di 2.7.55 ⋅ (MB m ML ) ∑ J⋅n tB MB braking time brake torque in s in Nm + ML when the load torque has a braking effect (higher brake torque – hoisting).7.16 Braking time (from beginning of brake action) tB = 9. + ML when the load torque increases the starting torque (overhauling loads can be considered as negative load torques – lowering).15 Starting time tA = 9.11 sec.55 ⋅ (MA m ML ) ∑ J⋅n tA MA ML starting time starting torque load torque in s in Nm in Nm – ML when the load torque is opposed to the starting torque (hoisting).035 ..p65/0299 29 . for sizes KB 71–125. 0. n ⋅ tA 60 ⋅ 2 n ⋅ tB n ⋅ tR + 60 ⋅ 2 60 2. 203255k2.7.. 8. motors may be provided with special windings for non-standard operating conditions.5 0.eps Depending on the motor frame size or number of poles. kT = Factor for non-standard coolant temperature kT kH = Factor for non-standard installation altitude 1.3 40 50 60 70 80 T [°C] 41217744.4 0.eps 41217544. for a coolant temperature of 40 °C and up to an altitude of 1000 m above sea level. for installation altitudes higher than 1000 m above sea level.8 Motor selection 2. unless otherwise specified. the given motor power must be reduced by factor kT.1 Ambient temperature and altitude The power ratings given in the tables refer to continuous duty operation S1 according to EN 60034 (IEC 34-1). check whether the motor with the next highest power rating meets the requirements. For higher coolant temperatures. Motor derating is not necessary if the ambient temperature (coolant temperature) is lowered with the installation altitude according to the adjacent table.9 0.8 0. 30 . Installation altitude above up to Maximum coolant temperature m m °C 0 1000 40 1000 2000 32 2000 3000 24 3000 4000 16 This results in a permissible motor power of: Pzul = PN ⋅ k T ⋅ k H Abbreviation Pzul PN kT kH Description Permissible motor power Rated power Factor for non-standard coolant temperature Factor for non-standard installation altitude Unit kW kW – – 203255k2. it must be reduced by factor kH.7 6 and 8 poles 0.2.p65/0299 If the permissible motor power is no longer sufficient for the drive.6 12 poles 0.0 2 and 4 poles 0. 4 0.5 0.0 0.2 0.6 JM JM + JZus kP 1 0. value z0 is recalculated according to the following equation: Abbreviation Description No-load starting frequency from list at 50 Hz New frequency other than 50 Hz No-load starting frequency for new frequency Unit h-1 Hz h-1 z0 X = z0 ⋅ 50 2 Hz 2 fx 2 z0 fX z0X Permissible starting frequency Z can be determined according to the following equation: Abbreviation Description Permissible starting frequency No-load starting frequency from list at 50 Hz Load torque factor during acceleration External moment of inertia factor Factor for required power and cyclic duration factor Unit h-1 h-1 – – – z = z0 ⋅ k M ⋅ k FI ⋅ k P z z0 kM or z = z0 X ⋅ k M ⋅ k FI ⋅ k P kFI kP Acceleration torque k M = 1− kM 1.eps 41652044.6 0.5 0.3 P1/PN = 0 0.0 0.eps kM k FI JM Jzus = = = = Factor for load torque during acceleration Factor for the external moment of inertia Motor inertia External moment of inertia referred to the motor shaft 203255k2.2 0.0 0.8 0.2 0.2 80 100 ED in % 1.p65/0299 31 .0 M MA 0.1 0.eps 41217944.9 0.9 1.1 0 1 2 3 4 5 J Zus JM 41217844.6 0.2.8 0.9 0.2 0.6 0.2 Determining the permissible starting frequency No-load starting frequency Z0 is specified in the motor power tables.9 1.8 0.1 0 0.4 0.7 0.4 0. The no-load starting frequency defines how often a motor can accelerate the moment of inertia of its rotor without load torque at 50 % CDF to its no-load speed within an hour.5 0.4 0. the external moment of inertia and the cyclic duration factor.8 0.6 External moment of inertia Required power and cyclic duration factor M MA k FI = k FI 1.3 0.7 0.7 0.9 0.3 0.2 0.5 0.4 0.7 0.8. For frequencies other than 50 Hz.1 0 0 20 40 60 1.3 0.1 0.8 0. Permissible starting frequency Z takes into account the load torque.7 0.5 0. Calculation of the starting frequencies is an approximation and is intended as a guide value for design purposes. you are advised to contact the technical department in our head office. Pole-changing motors are partly decelerated regeneratively by the large pole winding. whereby brake torques up to 3-times the motor starting torque may occur depending on the pole number ratio and/or winding design.p65/0299 . After determining the permissible motor starting frequency. check whether the brake is also suitable. In the case of counter-current braking. 32 203255k2. If the calculated starting frequency is close to the required value. For approximate calculation. the calculated starting frequency may be reduced by 50 %.Calculation of the permissible starting frequency is based on mechanical braking. Motor loss increases with electrical braking. the calculated starting frequency corresponds to approximately one quarter of the number of permissible starts without electrical braking. which should be avoided in practice. 2. so that the motor winding can assume the ambient temperature. Disconnect motor.42 for insulation class F 1 R2 R1 T2 T1 Ta Resistance of winding at the end of test Resistance of cold winding at T1 at the beginning of test Temperature of winding at the end of test Temperature of cold winding Temperature of cooling medium at the end of test in W in W in °C in °C in °C 203255k3. Measure winding resistance R2 and temperature of cooling medium (ambient temperature) Ta. Measure winding resistance R1 and winding temperature (ambient temperature) T1.2.p65/0299 33 .96 (IEC 34-9) (A-rated noise leveI).10 Measurement of temperature rise of windings 1. Operate motor and driven machine until the resistance values stop rising. R2 Formula for an approximate check: R £ 1. Temperature rise ϑ= R2 − R1 ⋅ (235 + T1) + ( Ta − T1) R1 [K ] T2 = ϑ + Ta should not exceed 105 K for insulation class F. 2. SB motors are below the prescribed maximum values according to EN 60034-9 / 05. 3. Leave motor and driven machine for several hours in the test room. 4.9 Noise The noise levels of KB. 2. 2.5 V DC output voltage and 4 kW tripping resistance. 34 203255k3. PTC thermistors to DIN 44081 are suitable for tripping devices with 2. PTC thermistors used for warning purposes are supplied with a rated tripping temperature 10 K lower than that of PTC thermistors used for switching off. an additional tripping device and double the quantity of PTC thermistors are required.1 PTC thermistors PTC thermistors can be integrated into the winding for motor protection at an extra price. – 1 temperature detector in the low-speed winding. 3 temperature detectors in the high-speed winding. The resistance for each PTC thermistor is between 10 and 250 W at temperatures of –20 °C to qNat –20 °C (Nat = rated tripping temperature). Temperature detectors integrated in the motor winding are only suitable for protection against thermal overload. – 1 temperature detector in the high-speed winding. a warning is required when the winding temperature is too high. • Special design (must be specified in the order): 3 PTC thermistors in the low-speed winding. Number of temperature detectors: • Motors with one winding: 1 temperature detector • Motors with two windings: 2 temperature detectors. 3 PTC thermistors in the high-speed winding. blocked rotor. excessively high starting frequencies. The required tripping devices must be ordered separately. two-phase starting. in addition to PTC thermistor switch-off. protection against overload. Note: If.11 Winding protection 2. The control voltage should not be less than 110 V and not exceed 250 V according to EN 60204. excessively high starting frequency. • Special design (must be ordered separately): 3 temperature detectors in the low-speed winding. blocked rotor. inadequate cooling. No protection against blocked rotor and two-phase starting. Number of PTC thermistors: • Motors with one winding: 3 PTC thermistors (1 per phase). excessively high starting frequency. The resistance of each PTC thermistor changes in the kW range when the rated tripping temperature is reached.11. 1 PTC thermistor in the low-speed winding. Important: Thermistors only provide protection against overload. inadequate cooling. two-phase starting.11. protection against overload. Not possible for frame sizes < 90 for design reasons. • Motors with two windings: 3 PTC thermistors. inadequate cooling.p65/0299 . Protection in the event of short circuit and a blocked rotor is not provided since temperature detector tripping times are significantly longer than those of PTC thermistors. 2 PTC thermistors in the high-speed winding.2 Temperature detectors Bimetallic temperature detectors can be integrated in the winding to protect the motor at an extra price. The temperature detector type required depends on the control voltage and control current. Connection diagram L4 L1 L2 L3 F2 F2 F3 F1 F1 Fuse motor F2 Thermal overcurrent relay F3 PTC thermistor tripping device H1 Signal lamp ON H2 Signal lamp FAULT K1 Power contactor S1 Push button OFF S2 Push button ON F3 K1 S1 F2 S2 K1 K1 U V W 3 M ~ 102 101 K1 L5 H1 H2 F3 A1 T> A2 P1 (T1. via a small transformer. 270 ca. SB 71 80 90 100 112 125 140 160 180 200 225 Heating capacity PH W ca. 25 ca. 45 ca. 160 ca.p65/0299 35 . 9 416 006 44. Guide values for the required heating capacity: Motor size KB. Z1) P2 (T2. 60 ca.12 Anti-condensation heater At standstill brake motors can be heated by supplying the motor winding with DC or AC resp.eps 2. 500 For further details see list 030 403 84. 350 ca. Please consult us for the currents which are permissible for the different cases. 203255k3. 85 ca. 200 ca. 120 ca. Z2) Fig. 35 ca. reverse On contactors Control fuses Auxiliary contactors Slip-ring rotor starting resistor Transformer for heating with AC Transformer with rectifier for heating with DC For slip-ring motors: As for squirrel-cage motors. 11 416 008 44.eps R tot = 2 ⋅ Rphcold U= = PH ⋅ 1 . K6 R T1 T2 Push button Contactor forward. 12 416 009 44. S2. but with short-circuiting of rotor.eps Circuit diagram for anti-condensation heater. Slip-ring motors: with K7 and R.p65/0299 . K2. S1. 10 416 007 44.2 ⋅ R tot I= = PH U= K7 L5 K1 K2 K3 K4 K5 K6 Fig. K7 F1 K5.Anti-condensation heater using the motor winding For squirrel-cage motors: AC heating L1 L2 L3 K1 F1 U T2 T1 Fig. K4 K1. Squirrel-cage motors:without K7 and R. S3. 36 203255k3. Heating by supplying the motor winding with AC or DC resp.eps K3 F2 K2 K4 U~ i~ on request K U1 V1 W1 R L M 1 3 4 5 6 W2 M 3 U2 V2 DC heating K7 2 L4 U= K5 K1 K6 K5 K4 K2 K6 K3 S1 S3 S2 K5 S4 K6 Fig. S4 K3. p65/0299 With the micro motor power off or in the case of mains failure. When the micro motor is energized while the main motor is switched off. At rest the rotor of the main motor is braked by the micro motor brake through the intermediate gear. 37 .eps The microspeed unit is a combination of two brake motors and an intermediate reduction gear. application examples Fig. the micro motor rotor and the main motor brake which functions as a clutch. the brake ring of the brake disc is released from the braking surface on the brake drum by rotor displacement so that the connection to the intermediate gear ceases to exist. The speed of the output shaft is now = speed of micromotor gear ratio of intermediate gear 203255k3. 13 41239844. With the main motor energized. The output shaft runs either at the speed of the main motor or at the speed of the micro motor reduced by the ratio of the intermediate gear.3 Microspeed units 3. the micro motor brake stops the unit through the positive connection between main motor brake disc and brake drum on the drive shaft of the intermediate gear.1 Brief description. the speed of the micro motor is reduced by the intermediate gear according to its gear ratio and its output is transmitted to the main motor shaft through the main motor brake which functions as a clutch. The shaft runs at the normal speed of the motor. 2 Connection Squirrel-cage motors are connected to direct-on-line starting. The weaker brake spring necessary for the Y/D connection of the micro motor would mean a correspondingly lower brake torque for the entire unit.2.3.8. 3.3 Electrical characteristics 3.2. A weaker brake spring would reduce the frictional torque between brake disc and brake drum.1.1 Size symbols (Short form) Example: KBA 100 A 4 + FG 06 + KBA 80 A 4 Main motor Intermediate gear Micro motor For detailed designation see mounting code and designations FG microspeed units. 3. 200 140 84.1.1 Motor data For all technical data and other details concerning the electrical characteristics of main and micro motor which are not mentioned in this list see the data lists of the corresponding motor.2 General information 3.2 Application examples Multi-speed drives on machine tools Positioning drives Feed drives Precision setting in mechanical engineering Crane drives Physical measuring devices Multi-speed drive units 3. practically irrespective of the load 3. In this connection see 3. so much that the full output of the micro motor could not be transmitted.3.2 Specifications. no.1 Advantages Compared with pole-changing motors the microspeed units have the following advantages: • higher speed ratio • precise stop with micro motor for positioning through reduction of effective load inertia • micro motor allows more starts per hour compared with slip-ring motors: • microspeed constant. The data are based on a frequency of 50 Hz.5.p65/0299 . Y/D start is not permitted since in the star connection the reduced axial thrust of the main motor requires a weaker brake spring.3. ident. standards See corresponding motor type. 38 203255k3. Consideration must be given to the fact that due to the gear ratio of the intermediate gear many values of the micro motor change if referred to the main shaft. 3. g. coupling.8 Increase in static pressure D pmax Pa Output Nominal current at 400 V 3 AC Weight kW A kg 3.2 Direction of rotation Main motor and micro motor must be connected for opposite directions of rotation to obtain the same direction of rotation at the output shaft of the main motor when the main and micro motors are running.4 5 20 730 0. enamel. balancing.3.4. e. Sizes and technical data Main motor Size 100-140 160 180-225 Air flow Vmax m3/min 5. for which there are several possibilities: • Fitting an infinitely variable mechanical gear between three-phase micro motor and intermediate gearbox (on request). condensation water drain holes. When the required arrangement differs from the standard arrangement please state the position of the terminal boxes and intermediate gear according to the mounting code.3 Terminal box 3. bearings.07 0. outdoor mounting. shaft extension.0 350 0. • Control of three-phase micro motor by an inverter (on request).5 Further details For all further details concerning the mechanical characteristics.3 Stepless micro motor operation The micro motor speed can also be delivered in a stepless speed range.4.4 Separate cooling Main motors which are to have separate cooling are equipped with a fitted separate fan.4 4. axial displacement. For vertical and inclined mountings see “Description” for motors. Standard position for main and micro motor: right-hand side (facing the shaft extension of main motor). cooling.13 0.4 10.4 Mechanical characteristics 3. 3.4. direction of axial displacement when braking.4. type of enclosure. The output and switching frequency for the motor are increased as a result.p65/0299 39 . 203255k3. 3.1 Mounting For foot and flange mountings see mounting code. 3.3.5 1. see section 2.5 D 04 x Separate fan size D 05 D 06 x x 10 430 0.4. 5 Brake 3. arrangement The intermediate gear is the mechanical link between micro and main motor. 3. brake torque reduction is possible. 3. The speed of the micro motor is reduced by the intermediate gear and then transmitted to the main shaft. 4 BEG BVK BVK radial BLK BLK radial It must be checked whether it is possible to fit the units to the motor on the basis of the dimension drawings. 3. 3. For possibilities see 2. not for hoisting operation. e.6. 2.p65/0299 The intermediate gear is a triple-stage spur gear. for micro motor. 3. It must be checked whether it is possible to fit the unit to the motor on the basis of the dimension drawings.5.g.6 Intermediate gear.5.5 Clutch Brake disc of main motor and brake drum make up the clutch to the intermediate gear.2 Brake torque reduction For main motor only advisable in the case of special technical requirements.3 To cancel brake action Fitting of additional equipment to micro motor (not for hoisting operation). The range of speed ratios is approximately 4 : 1 to 125 : 1. 4 BVK radial BLK radial HBLG LAG EBLG BLE 3. The exact values are indicated in the data lists.3.1 Brake disc For main and micro motor • Standard: light conical brake disc with low moment of inertia J On request: • Heavy conical brake disc with high moment of inertia J J approximately 2 – 3 times motor J Longer starting and braking time. • • • • • • • Manual brake release attachment Load lowering attachment Electric brake release attachment Brake release device Brake torque setter attachment Brake wear checking device axial Brake wear checking device radial (in case another additional equipment is mounted axially) • Brake release checking device axial • Brake release checking device radial (in case another additional equipment is mounted axially) • Canopy for brakes (to protect the brake) Additional equipment fitted to main motor • Brake release with remote control for main motor in microspeed unit • Load lowering attachment for main motor in microspeed unit • Brake wear checking device radial for main motor in microspeed unit • Brake release checking device radial for main motor in microspeed unit BLF 1 LAF 1.5. 3.5.5.4 Additional equipment Additional equipment fitted to the micro motor (not for hoisting operation). however.5.5. travel drives. For possibilities see 2.5. 40 . 203255k3. ranges WU. range D triple-stage spur wheel gearbox. WG. range AFM triple-stage angular gearbox. ident.7 Geared microspeed units The number of possible applications for microspeed units can be increased by fitting an output gearbox to the main motor. The following gearboxes can be used: • Old gearboxes – – – – – double-stage spur wheel gearbox. 203 150 44. 203255k3.p65/0299 41 . DF – double and triple-stage offset gearbox.3. WF In this connection see geared motors (catalogue with prices). range AFW • New gearboxes – double and triple-stage helical gearbox. no. AM – double and triple-stage angular gearbox. range AF double and triple-stage offset gearbox. range T triple-stage offset gearbox. ranges AU. ranges DG. AG. AF. eps 42 203255k3.3. 14 41415644. n1 = Speed at the main shaft during main motor operation Main motor speed The main motor speeds mentioned in the data lists are approximately 2800. 1400.8 Selecting a microspeed unit 3. They are also mentioned in the data lists.1 Symbols The following terms and abbreviations are used to facilitate the description of the required microspeed unit. Rated power of the main motor Rated torque of the main motor Clutch torque P = MN = MKU = Micro motor nF i Main motor n1 nH n2 Intermediate gear Fig. 900 and 700 rpm. Micro motor speed In general 4-pole micro motors for approximately 1400 rpm are mentioned in the data lists.8. Gear ratio of the intermediate gear nH = n1 nF = n1 i = n2 = nF i Speed at the main shaft during micro motor operation The speed of the micro motor nF is reduced by the intermediate gear according to gear ratio i and then transmitted to the main shaft.p65/0299 . 8. S 3 – 60% or S 3 – 15%. Limits for selection In this list the combination of micro motor/main motor is based on the following rules: The micro motor delivers at the main shaft • at least the full-load torque • at most the clutch torque of the main motor. 1400 rpm and then use the corresponding data list to choose main motor output at a duty factor of 100. Furthermore the main motor can be designed for a different duty factor. The torque (or brake torque) of the micro motor referred to the main shaft increases in proportion to gear ratio i of the intermediate gear and in the case of the high gear ratios it reaches very high values. 40. S 3 – 60 % or S 3 – 15 % • 2-pole micro motors.g. The use of output gearboxes fitted to the microspeed unit increases the number of possible applications (in this connection see section 3.g. a torque is required which is less than the clutch torque (e. The data lists additionally include micro motor combinations using the smallest micro motor KBL 71 A 4. If. especially to reach wide speed ranges • Pole-changing micro motors to obtain several microspeed steps • Inverter-fed micro motors obtain an infinitely variable speed range during microspeed operation. Due to the high reduction ratio this motor has a full-load torque which is higher than the transmittable clutch torque MKU.7). which cannot be transmitted because of the limiting clutch torque.2 Selection from data list First select a main motor. especially for small main motors • 6 and 8-pole micro motors. this micro motor is acceptable. The clutch torque of the main motor is in this case equal to the brake torque with conical brake disc (in the motor data lists designated MB1). e. 3.8. Next select the speed of the micro motor required at the main shaft of the speed ratio main motor/micro motor = gear ratio of the intermediate gear. e. which corresponds to the full-load torque of the main motor).3.3 Further possibilities for selection For all empty spaces in the data list please consult us. 203255k3. in these cases. To do this determine its approximate speed.g.g. or 25 %. Then read off micro motor size at the intersection of both lines and choose one of the three duty factors for the micro motor. The following not mentioned micro motors can also be used: • Micro motors for a different duty factor. For data of main and micro motors which are not mentioned in this list see the data list of the corresponding motor. e.p65/0299 43 . p65/0299 Printed in Germany DZS/0299/3T . 203255k3. • Take account of actual micro motor loading. 3. 44 Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH. 2. Checking mechanical fitting possibilities according to mounting code and find the size of the intermediate gear.6 Determination of exact speeds Main motor: Look up full-load speed from motor data list under “Rated speed”. Micro motor: The exact microspeed (speed of micro motor referred to main shaft) is obtained as follows: • Determine rated speed of micro motor from motor data list. 3.8. Subject to change. Determine micro motor from its data list. 3. 4. Select main motor from its data list. Taking account of the following facts: • Torque of micro motor at main shaft should be equal to or higher than torque of main motor. • The torque (full-load torque.8. • Divide this speed by the exact gear ratio. • The output power remains constant except for insignificant losses. D-58286 Wetter Not liable for errors or omissions. brake torque.5 Variation of data The listed data of the micro motor – referred to the main shaft and taking the gear ratio i of the intermediate gear into account – change as follows: • The speed decreases in proportion to gear ratio i. starting torque) increase in proportion to gear ratio i.3. 5.4 Selection without microspeed unit data lists The selection of a microspeed unit can also be made without the microspeed unit data lists: 1. • Torque of micro motor at main shaft should be equal to or less than clutch torque of main motor.8. Determine gear ratio of the intermediate gear. For all other data see data lists of the corresponding motor. The partial-load speed is correspondingly higher.