DEMAG ZBA User manual

240519 enGB 214 228 44 719 IS 919
41807744.eps
Assembly instructions
ZBA, ZBE, ZBP, ZBF brake motors

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21422844_en_240519.indd
Contents
Further documents
Manufacturer
Original assembly instructions
Demag Cranes & Components GmbH
Forststrasse 16
40597 Düsseldorf, Germany
www.demagcranes.com
[email protected]
The metric system is used in this document and all figures are shown with a
comma as the decimal separator.
1 Foreword 4
1.1 Copyright 4
1.2 After-sales service 4
1.3 Liability for defects 4
1.4 Limitations of liability 4
1.5 Definitions 5
2 Safety 6
2.1 Symbols 6
2.2 Intended use 6
2.3 Prohibited practices, improper use 6
2.4 Personal protection equipment 6
2.5 General safety information 7
3 Technical data 8
4 Design and function 9
4.1 Motor 9
4.1.1 Motor type designation 9
4.1.2 Rating plates 10
4.1.3 Motor enclosures 11
4.2 ZB. motor brake 12
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_de 208 722 44_en 208 722 44_fr 208 722 44_es
Catalogues/technical data
Drive Designer Online www.demag-drivedesigner.com
Geared motors catalogue 203 150 44 203 151 44 203 152 44 203 153 44
DRS wheel block system catalogue 203 350 44 203 352 44 203 353 44 203 354 44
ZBL motor/A-type offset gearbox/DRS wheel block travel unit technical data 203 812 44_de 203 812 44_en – –
RS wheel block system technical data 202 553 44 202 597 44 – –
Demag DWS wheel set technical data 203 687 44 203 688 44 203 689 44 203 690 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
FG 06, FG 08, FG 10 gearbox assembly instructions 206 217 44 206 218 44 206 219 44 206 220 44
ZBL motor range assembly instructions 211 813 44_de 211 813 44_en 211 813 44_fr –
ZBA, ZBE, ZBP, ZBF motor assembly instructions 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
Assembly instructions for brake accessories – Z motor range 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
Encoders for Z motors, assembly instructions 214 371 44 214 372 44 214 373 44 214 374 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
DWS wheel set assembly instructions 214 132 44 214 133 44 214 134 44 214 135 44

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5 Motor/brake connection diagrams 13
5.1 B003 to B680 brake control 13
5.1.1 GE brake rectifiers (normal excitation) 14
5.1.2 GP brake rectifiers (normal excitation for pole-changing motors) 14
5.1.3 GS brake rectifiers (high-speed excitation) 15
5.1.4 GF brake rectifiers (normal excitation) 15
5.1.5 GU brake rectifiers (normal excitation) 16
5.1.6 SE current relays (motor current-dependent high-speed trip relay) 16
5.1.7 VE voltage relays (voltage-dependent high-speed trip relay) 16
5.2 Brake selection table 18
5.2.1 Brake power consumption 18
5.2.2 Electric connection, brake actuation times 19
5.3 Selection criteria 21
5.4 ZB motor standard connection diagrams to EN standard 22
5.4.1 ZBA/ZBE/ZBP standard motors, fitted with a brake 22
5.4.2 ZBF travel motors 22
5.5 Connection diagram selection 23
5.5.1 Line operation 23
5.5.2 Inverter operation 27
5.6 Connection diagrams 28
5.7 Connecting temperature and brake monitoring devices 61
6 Transport, packing, storage 62
6.1 Safety warnings 62
6.2 Transport inspection 62
6.3 Packing 62
6.4 Storage 62
7 Assembly 63
7.1 Checking the condition of the motor 63
7.2 Checking the installation location 63
7.3 Installing the motor 63
7.4 Special instructions for installing the motor 63
7.5 Corrosion protection following installation by the customer 63
7.6 Changing the terminal box position at a later date 64
7.7 Instructions for connecting the motor 65
8 Putting the unit into service 66
8.1 Safety warnings 66
8.2 Requirements 67
8.3 Check when commissioning 67
8.4 Geared motors 67
9 Maintenance 68
9.1 Safety instructions 68
9.2 Inspection before starting work and during operation 69
9.3 Maintenance schedule 69
9.4 B003 - B680 brakes 70
9.4.1 Removing and fitting the fan cover and fan 71
9.4.2 Checking and adjusting brake air gap s1 72
9.4.3 Replacing the brake disc 74
9.4.4 Brake spring arrangement and associated brake torques 78
9.4.5 Bolt tightening torques 82
9.5 Options 83
9.5.1 IP55/IP65 sealing arrangement for B003 - B680 brakes 83
9.5.2 Reduced noise level 84
9.5.3 Manual brake release 84
9.5.4 Microswitches 84
9.5.5 Emergency-stop brake lining 84
10 Troubleshooting 85
11 Declaration of conformity 86
Declaration of conformity 87

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1.3 Liability for defects
1 Foreword
You have purchased a Demag product. This equipment was manufactured in
accordance with state-of-the-art engineering principles.
These assembly instructions are designed to provide the user with appropriate
instructions for safe and correct work and to facilitate maintenance.
Every individual given the task of transporting, installing, commissioning,
operating, maintaining and repairing our products 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 operating personnel at all times in
order to prevent operating errors and to ensure smooth and trouble-free operation
of our products.
These assembly instructions must be treated confidentially. They should only be
used by authorised personnel. They may only be made available to third parties
with the written approval of the manufacturer. All documents are protected within
the sense of copyright law.
No part of this documentation, in whole or in part, may be reproduced, distributed,
used or published in any way without specific prior consent. Infringements are
an offence resulting in obligatory compensatory damages. All industrial rights
reserved.
If you have any questions about our products or need technical information, etc.,
please contact our after-sales service.
The current addresses of the sales offices in Germany and the subsidiaries and
agencies worldwide can be found on our homepage at
www.demagcranes.com/Contact.
These assembly instructions must be read carefully before installing and putting
the product into operation.
We assume no liability for any damage or malfunctions resulting from failure to
comply with the assembly instructions.
Any liability claims for defects must be made by quoting the order number
immediately 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 delivery and services,
• use of non-genuine spare parts and accessories,
• refurbishment or modification of the product unless approved by the
manufacturer in writing.
Wearing parts are not subject to liability for defects.
1.2 After-sales service
1.1 Copyright
All technical information, data and instructions for operation contained in these
assembly instructions were up to date on going to print and have been 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 products which are the subject of these assembly
instructions.
The information, illustrations and descriptions contained in these assembly
instructions are therefore only intended for information purposes.
The descriptions and illustrations contained in these assembly instructions do
not necessarily correspond to the scope of delivery or any subsequent spare part
delivery, either; the drawing and illustrations are not to scale.
Only documentation belonging to the actual order is valid.
1.4 Limitations of liability

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We assume no liability for any defects, damage or malfunctions caused as a result
of operating errors, non-compliance with these assembly instructions or missing 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 unauthorised modification and conversion of the product
are not permitted and void any liability for defects or damage resulting therefrom.
With the exclusion of any further claims, our liability for defects and liability
obligations for any defects pertaining to the products supplied or faults in the
documentation delivered or any negligence on our part are exclusively based on
the provisions 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.
Manufacturer
The manufacturer is the person who:
1. manufactures the equipment under his or her own name and places it on the
market for the first time;
2. resells other manufacturers’ equipment under his or her own name, whereby
the reseller is not considered to be the manufacturer provided the name of the
manufacturer (as in 1.) appears on the equipment;
3. imports the equipment into the country and places it on the market for the first
time or
4. exports equipment to another member state of the European Union and hands it
over direct to a user in that country.
Owner
Owners (employer, company) are defined as persons who own the product and
who use it as intended or allow it to be operated by suitable and trained persons.
Operating personnel
Operating personnel are defined as persons assigned by the owner of the product
to operate the product. This person must be trained by the owner in accordance
with the tasks to be performed.
Trained person
Trained persons are defined as persons who have been instructed for the tasks
assigned to them and on the possible hazards resulting from inappropriate
conduct. Personnel must have been informed about required safety equipment,
protective measures, relevant regulations, codes of practice, accident prevention
regulations and operating conditions and has provided verification of their
competence. This person must be trained by the owner in accordance with the
tasks to be performed.
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.
This person must be trained by the owner in accordance with the tasks to be
performed.
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.
This person must be trained by the owner in accordance with the tasks to be
performed.
Experienced technician
Experienced technicians are defined as persons who, owing to their technical
training and experience, have sufficient knowledge in the field of the product.
These persons must be familiar with the relevant national industrial safety
regulations, codes of practice, accident prevention regulations, directives and
generally accepted engineering standards (e.g. EC directives, VDE regulations,
DGUV) enabling them to judge the safe operating condition of the product.
1.5 Definitions

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2 Safety
2.1 Symbols The following symbols and instructions warn against possible injuries or damage
and are intended to assist you in your work.
DANGER.
This symbol indicates an immediate hazard which can result in serious injury
or death.
– Follow these instructions at all times and be particularly careful and cautious.
WARNING.
This symbol indicates a possibly hazardous situation which might result in
serious injury or death.
– Follow these instructions at all times and be particularly careful and cautious.
CAUTION.
This symbol indicates a possibly hazardous situation which might result in
medium to light injury.
– Follow these instructions at all times and be particularly careful and cautious.
2.2 Intended use
2.3 Prohibited practices,
improper 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, site
altitude).
Under certain conditions, operation of standard motors is prohibited as this can
result in malfunctions, equipment failure or danger to life and limb, e.g. in the case
of:
• Areas where acidic, corrosive air is used as a 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 electric components.
Safety devices must not be rendered inoperable or modified or used in any way
other than that for which they have been designed.
2.4 Personal protection
equipment
When work is carried out on or with the machine, the following protective
equipment is recommended to be worn according to the owner’s hazard
assessment:
• Protective clothing, closely fitting working clothes (low tear strength, no loose
sleeves, no rings or any other jewellery, etc.);
• Safety shoes to protect against falling parts and against slipping;
• Safety helmet to be worn by everybody in the danger zone.
IMPORTANT. Operating hazard for the product.
• This symbol indicates information on the appropriate use of the product.
• This symbol indicates all warnings which, if not complied with, can result in
malfunctions or damage.
i
iNOTE. This symbol indicates useful information and tips for efficient use of the
product.

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2.5 General safety
information
People under the influence of drugs, alcohol or medicines which affect
their reactions must not install, operate, put into service, maintain, repair or
disassemble motors.
Any conversions and modifications to the products require the written consent of
the manufacturer.
Work on electric equipment may only be carried out by qualified electricians in
accordance with electric engineering regulations. Motors must be brought to a
standstill and switched off immediately if a malfunction occurs
Malfunctions must be eliminated immediately.
National accident prevention regulations and codes of practice and general safety
regulations must be observed when operating our products. Important information
and instructions are marked by corresponding symbols.
Follow these instructions and safety regulations to avoid accidents and damage.
The assembly instructions must be kept available at the place where the motors
are in use at all times. They include significant aspects and appropriate excerpts
from the relevant guidelines, standards and regulations. The owner must instruct
his personnel appropriately.
Any failure to follow the safety warnings in these assembly instructions can result
in death or personal injury.
Observe general statutory and other obligatory regulations relating to accident
prevention and environmental protection and basic health and safety requirements
in addition to those included in these assembly instructions. Such requirements
may also relate, for example, to the handling of hazardous materials or the
provision/wearing of personal protection equipment. Comply with these regulations
and general accident prevention regulations relevant for the place where motors
are used when working on motors.
Motors can still constitute a danger to life and limb if they are not installed,
operated, maintained or used as intended by personnel who have not been
trained or specially instructed. The assembly instructions must, if required, be
supplemented by the owner with instructions and information (e.g. operating
procedure instructions) relating to organisation of work, working procedures,
operating personnel, etc. Supervising and reporting obligations as well as special
operating conditions must also be taken into consideration.
Personnel assigned to working on motors must have read and understood the
assembly instructions and, in particular, the safety information contained in
them. All activities relating to motors which are not described in these assembly
instructions may only be carried out by specifically trained specialist personnel.
The owner must ensure that personnel work in a safety and hazard-conscious
manner in compliance with the assembly instructions.
The owner must ensure that motors are only operated when in proper working
order and that all relevant safety requirements and regulations are fulfilled.
Motors must be taken out of service immediately if functional defects or
irregularities are detected. In the event of a stoppage (e.g. if defects regarding
safe and reliable operation are detected, in emergency situations, in the event of
operating malfunctions, for maintenance purposes, if damage is detected or after
finishing work), the operator/experienced technician must carry out all prescribed
safety measures.
All safety and hazard warnings on motors must be kept in complete and in legible
condition.
Modifications, additions to and conversions of motors which can impair safety in
any way must not be carried out without the written consent of the manufacturer.
Safety devices must not be rendered inoperative.
Only genuine Demag spare parts and accessories may be used. Observe
prescribed deadlines or those specified in the assembly instructions for routine
checks/inspections.

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3 Technical data
Function conditions for standard design
Conditions ZB range
Transport temperature -20 ... +40 °C
Storage temperature 0 ... +40 °C
Storage conditions Dry, indoors
Ambient operating temperature -20 ... +40 °C
Environment 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 400V/50 Hz 480V/60 Hz 500V/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
(line operation)
Motor frame size with occasional emergen-
cy stop
(inverter operation)
ZBF 63 – 132 3600 ––
ZBA 63 – 132
ZBE 63 – 80A
ZBP 80B – 132 3600
ZBA/ZBE 63 – 100
ZBP 80B – 100 5000
ZBA/ZBE/ZBP 112 – 132 4000
ZBA/ZBE/ZBP 160 – 180A, with B140 brake
ZBA/ZBE/ZBP 160 – 180A 3600
ZBA/ZBE/ZBP 160 – 180A, with B280 brake
2000
ZBA 180B – 225 ZBA/ZBE 180B – 225 3000

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4 Design and function
4.1 Motor
4.1.1 Motor type designation
The range of Demag cylindrical-rotor motors includes ZBA, ZBE, ZBP and ZBF
motor types.
The ZBA motor range consists of motor frame sizes 63 to 225 with 2, 4, 6 and 8
poles. ZBE motors have 4 poles, the motor range consists of frame sizes 63 to
225 in efficiency class IE2. The ZBP motor range includes frame sizes 80 to 180
of 4-pole design in efficiency class IE3. The Z motor range includes pole-changing
designs and ZBF 63 to 132 motors with integrated flywheels for particularly smooth
load movements.
The housings of ZB. 63 to ZB. 132 motors are made of a high-quality aluminium
alloy with an integrated terminal box base. They have a die-cast aluminium fan
cover and a die-cast aluminium terminal box cover.
Motor frame sizes ZB. 160 to ZB. 225 have a grey cast-iron housing with a fitted
terminal box made of die-cast aluminium and a sheet-steel fan cover.
ZBA, ZBE and ZBP motors can be supplied in flange and foot design and also
fitted to Demag gearboxes. Demag motors are supplied with only one shaft end.
The connection dimensions largely correspond to IEC Publication 72-1. The foot
motor largely corresponds to DIN 42673, the flange motor corresponds to DIN
42677.
No. of poles
2, 4, 6, 8, 8/2, 12/2, 12/4
Rating class
A, AL, B, C
Size
ZBA: 63, 71, 80, 90, 100, 112, 132, 160, 180, 200, 225
ZBE: 63, 71, 80, 90, 100, 112, 132, 160, 180, 200, 225
ZBP: 80, 90, 100, 112, 132, 160, 180
ZBF: 63, 71, 80, 90, 100, 112, 132
Motor type
ZB Cylindrical-rotor brake motor
Z B A 100 A 4 B050 B3 1
Terminal box position
0, 1, 2, 3
Mounting code to DIN
EN60034-7, only needs to be
specified for solo motors
B3, B5, B6, B7, B8, B14, V1,
V3, V5, V6, V18, V19
Application code
AMotors for general applications and intermittent duty
EMotors for general applications with efficiency class IE2
P Motors for general applications with efficiency class IE3
FMotors for travel applications
Brake size
ZBA: B003, B007, B020, B050, B140, B280, B680
ZBE: B003, B007, B020, B050, B140, B280, B680
ZBP: B007, B020, B050, B140, B280
ZBF: B003, B020, B050, B140

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ZB. 63 A to ZB. 71 B motor rating plate
The rating plate is arranged to the left or right of the terminal box on the motor end cap, e.g.
4.1.2 Rating plates
ZB. 80 A to ZB. 132 C motor rating plate
The rating plate is arranged to the left or right of the terminal box base, e.g.
ZB. 160 A to ZB. 225 B motor rating plate
The rating plate is arranged to the left or right next to the terminal box on the stator, e.g.
43601944.eps
43602045.eps
43602145.eps
Manufacturer, country of origin, regulation
Type designation, number of phases, enclosure, temperature class, model
Motor number, duty factor, power factor
Motor weight, inertia factor, frequency, power factor
Speed, switching frequency, ambient temperature > 40 °C
Connection, voltage, current
Brake: braking torque, supply voltage, coil voltage, coil current
Order number, entry number
Model, motor weight, inertia factor
Type designation, number of phases, enclosure
Motor number, temperature class, duty factor
Output, power factor, frequency
Order number, entry number, energy efficiency class
1
2
34
5
6
7
8
1
3
45
6
7
8
2
10
9
13
7
1
5
6
11
12
4
11
1
2
3
5
6
7
9
8
10
12
13
Demag Cranes & Components GmbH
Made in Germany
A
Type: ZBA 160 B4 B280
Mot.Nr: 12345678
183 kg Fl:
1440
230
Y 400
185 Nm
ANR: 59021500
Bremse:
1/min
V 51,00
AC 400 V DC 180
ASN:19301
V 29,0
F
60
cos
c/h
V 0,45
60
0,84:50 Hz
%ED 15,0 kW
°C
IM B3-1Iso.:IP 543
EN 60034-1
~
A
A
Demag Cranes & Components GmbH
43601945.eps
Made in GermanyDemag Cranes & Components GmbH

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4.1.3 Motor enclosures ZB motors are supplied with IP 54 as standard. For brake sizes B003 - B680, IP 54
dust protection only applies for non-magnetic and non-magnetisable particles in
this case. All motors are available with IP 55 and IP 65 enclosure, on request,
which then also provides protection against magnetic or megnetizable particles.
Brief explanation of enclosures:
Protection against harmful dust accumulation, protection against splashwater from
all directions.
Protection against harmful dust accumulation, protection against hose-water from
all directions.
Detailed descriptions of these enclosures and test methods can be found in
EN 60034 part 5 (DIN VDE 0530, part 5).
Complete protection against dust accumulation, protection against hose-water
from all directions.
Detailed descriptions of these enclosures and test methods can be found in
EN 60529.
If a motor is operated under arduous conditions outdoors, e.g. unprotected
installation in wind and rain or installation at great heights, standard IP 54
enclosure may not be sufficient.
In these cases the motor must be provided with IP 55/IP 65 enclosure or protected
by suitable measures, e.g. wind and rain deflector. For vertically mounted motors
with the shaft facing downwards, a canopy/round protection panel is available at
an extra price.
IP 54
IP 55
IP 65
Outdoor operation

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4.2 ZB. motor brake Demag B003 and B680 disc brakes are double-surface spring-actuated brakes
featuring electro-magnetic brake release. The brake fitted under the fan cover can
be controlled independently of the motor and causes no axial movement of the
rotor shaft or forces on the bearings.
The diagrams show the function elements of the disc brakes, which are spring-
actuated with electro-magnetic release.
When the voltage supply to the brake coil is interrupted, the brake is applied. This
operating principle is also known as a safety brake.
B003 to B680 brakes are controlled as standard by a brake module integrated
in the terminal box of the motor. Brake sizes B003 to B050 can also be fed by a
separate supply to the coil.
Two brake sizes are possible for each motor frame size to cover a large brake
torque range for various applications.
The brake is provided with IP 54 enclosure as standard. If the enclosure type is
increased to IP 55/IP 65, an additional covering tape (15) must be used, which
is fitted to an additional retaining plate (16) for ZBF 80 - 132 units. Supporting
washer (17) is added to shaft sealing ring with worm spring (7), the intermediate
space is filled with grease. An additional plastic washer (18) is fitted beneath
adjusting nut (12).
B007 – B680 DC brakesB003 DC brake
1 Brake end cap
2 Carrier
3 Brake disc
4 Armature plate
5 Stop plate
10 Threaded pin
11 Distance spring
12 Adjusting nut
13 Brake spring
14 Collared pin
6 Electro-magnet
7 Radial shaft sealing ring
8 Friction plate
ZBA 63-132 (B050), ZBE 63-132 (B050),
ZBP 80-132 (B050), ZBF 63/71
9 Sleeve
41687358.eps
42282446.eps
For IP55/IP65
15 Covering tape
16 ZBF 80-112 retaining plate
(B050)
17 Supporting washer
18 Plastic washer
5
1347
810 11 12 13
6
9
15 18
12 3
413 7
12
856
11
14
15
16 17

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5 Motor/brake connection diagrams
Supply and brake voltage
Uline [AC] Ubrake [DC]
230 V
400 V
104 V
180 V
5.1 B003 to B680 brake
control
Various control modules are available which are fitted in the brake motor terminal
box as standard for controlling Demag B003 to B680 disc brakes with DC
magnets.
All control modules are protected by varistors against overvoltage at the AC input
and on the switching contact terminal as standard.
An installation set (part no. 260 807 84) is available for fitting control modules in a
switchgear cabinet.
It makes it possible to install
• a single module (GE, GS, GP, GF, GU) or
• a combination of modules (e.g. GP + SE)
For separate supply from the installation control system, and when the control
modules are fitted in the switchgear cabinet, an additional brake varistor
(260 898 84) must be connected to the brake connection in the terminal box of the
brake motor.
If required, the motor must be fitted with varistors.
Brakes up to size B050 for ZBA/ZBE/ZBP motors and B140 for ZBF motors can
also be supplied with 24 V DC from the installation control system.
GF and GP brake rectifiers can be used parallel to the motor winding for pole-
changing motors.
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 interruption
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 have 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 an inverter.
DC control should generally be provided for ZBF motors.
IMPORTANT. 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.
i

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Assignments
Brake control module overview
Excitation modules Switch-offmodules 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
GF - Combined module Normal excitation for pole-changing motors and motor cur-
rent-dependent high-speed switch-off
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
5.1.1 GE brake rectifiers (normal
excitation)
5.1.2 GP brake rectifiers (normal
excitation for pole-changing
motors)
GE brake rectifiers are used for single-speed motors as standard, and for pole-
changing motors that have 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.
GP brake rectifiers can be used parallel to the motor winding for pole-changing
motors that have separate windings. They are used up to brake size B050 for ZBA
motors and B140 for ZBF motors.
In this case, both windings must 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.
No additional cables are necessary when SE units are used.
No additional cables are necessary when SE units are used.
IMPORTANT. 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.
When used with a pole-changing motor, GE modules must be provided with a
separate power supply or according to connection diagram 037 860 84 (see
section 5.5).
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IMPORTANT. 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 modules.
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5.1.4 GF brake rectifiers (normal
excitation)
GF combination modules combine three functions in one unit and are supplied
together with the motor winding.
As standard, GF brake rectifiers are 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 no 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.
5.1.3 GS brake rectifiers (high-
speed excitation)
GS brake rectifiers include a reversible rectifier and are used for ZBA, ZBE and
ZBP motors with brakes as of size B140 as standard. In this case, the module
must be supplied via 3 phases at terminals 5, 6 and 7. (Overexcitation factor of
2,5).
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 up to B140). In this case, a 2-phase supply at
terminals 5 and 6 is sufficient (overexcitation factor of 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 second to release it and then supplies it with the appropriate holding voltage
from a half-wave rectifier.
To ensure the unit switches with overexcitation and, therefore, correct functioning,
the following minimum times must be maintained between switch-off and restart.
Combinations with GE/VE or GS/VE modules must be used for inverter operation.
Switch-offmethod: In DC circuit With GS + VE/SE In AC circuit
Interval 100 ms 250 ms 1,5 s
No additional cables are necessary when SE or VE units are used.
IMPORTANT. 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 modules.
When used with a pole-changing motor, GS modules must be provided with a
separate power supply or according to connection diagram 037 886 84 (see
section 5.5).
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IMPORTANT. GF modules must not be used together with an inverter (due to
motor current detection) and may only be supplied with voltages between 220 V/
AC and 500 V/AC.
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5.1.5 GU brake rectifiers (normal
excitation)
5.1.6 SE current relays (motor
current-dependent high-speed
trip relay)
5.1.7 VE voltage relays (voltage-
dependent high-speed trip
relay)
GU brake rectifiers can be used as an option for brakes with a separate AC power
supply up to brake size B050.
They are fitted in the brake motor terminal box as standard, but can also be
alternatively used in a switchgear cabinet. 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 24 V/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
application time to be achieved.
It is not necessary to control the brake via the AC power 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.
SE current relays can be combined with GE, GS and GP brake rectifiers. They
are used for rapid demagnetization of the brake to achieve fast brake application
times without the need for additional wiring for brake switch-off in the DC circuit.
SE current 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.
VE voltage relays can be combined with GE, GS and GP brake rectifiers. In
contrast to SE current relays, VE voltage relays must only be used for brakes with
a separate power supply. These modules can 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.
If the brake is to be released without motor current, it is also recommended that
the VE module be used instead of the SE.
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.
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NOTE. 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.
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GE and VE brake modules should be used for separate AC power supply for the
brake in combination with ZBF motors.
NOTE. 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.
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Brake control module fields of application
GE, GP, GS brake rectifiers, GF, GU combined module
Brake voltage Brake size
U AC
V
U DC
VB003 B007 B020 B050 B140 B280 B680
42 - 109 19 - 49 GE [3 A]
GP [3 A]
110 - 500 50 - 225
GE [3 A] 6)
GP [3 A] 7)
GS [1 A]
GE [3 A] 1) 6)
GP [3 A] 1) 7)
190 - 500 86 - 225 GS [1 A]
260 - 500 117 - 225 GS [1 A] GS [1 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 - 500 110 - 500 1) 190 - 500 260 - 500
U DC in V 19 - 225 50 - 225 1) 86 - 225 117 - 225
Modules VE 2 A voltage relay
SE 2 A current relay
U AC = Brake control module input voltage
U DC = Brake control module output voltage - brake supply voltage
Brake control module technical data
Module Part no. Voltage range V /AC Max. brake continuous direct
current I /A Note
GE 260 890 84 42 ... 500 3
GP 260 891 84 42 ... 500 3
GS 260 894 84 110 ... 500 5) 1 Overexcitation factor: 2 or 2,5 3)
GF 260 943 84 220 ... 500 0,8 0,25 ... 16 A for ZBF 63 - 100
GU 260 957 84 220 ... 500 0,8
The GU module is controlled direct by means of a 24 V/DC
switching signal (I switch: approx. 10,2 mA) from an installation
or a frequency inverter.
SE
260 864 84
42 ... 500 2
0,25 ... 4 A 4)
260 870 84 0,4 ... 16 A 4)
260 896 84 1,2 ... 50 A 4)
VE
260 901 84 42 ... 149
2
260 902 84 150 ... 500
1) Only for use with ZBF motors.
2) Optional for brakes with separate AC power supply.
3) 2 supply lines - overexcitation factor of 2
3 supply lines - overexcitation factor of 2,5 required for ZBA, ZBE and ZBP motors from brake size B140
4) Standard - Rated current of motor is equal to or smaller than the higher value of the SE current relay specified under “control current range” (single-phase
motor current).
5) Voltage range dependent on the brake size, see “Brake control module fields of application” table.
6) The previous GE 1,5 A module has been replaced by the GE 3 A module.
7) The previous GP 1,5 A module has been replaced by the GP 3 A module.

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1) SE modules are assigned according to motor rated current INas shown below:
5.2 Brake selection table
Brake Supply voltage
V AC
Assigned standard modules Standard brake torque
Note
ZBA/ZBE/ZBP ZBF ZBA/ZBE/ZBP ZBF
Single-speed or
pole-changing Single-speed Pole-changing
B003 42 - 500 GE [3 A] GE [3 A] + SE 1)
GF 3)
≤2,5 Nm ≤2,5 Nm
2)
B007 42 - 500 GE [3 A] GE [3 A] + SE 1) ≤7,6 Nm ≤2,3 Nm 5)
B020 42 - 500 GE [3 A] GE [3 A] + SE 1) ≤20 Nm ≤5,5 Nm
B050 42 - 500 GE [3 A] GE [3 A] + SE 1) ≤50 Nm ≤13 Nm
B140
42 - 109 – – –
≤140 Nm ≤37 Nm
4)
110 - 500 – GE [3 A] + SE 1) GP [3 A] + SE 1)
190 - 500 GS – –
B280
42 - 189 – – – ≤280 Nm –
260 - 500 GS – –
B680
42 - 259 – – – ≤680 Nm –
260 - 500 GS – –
2) Power supply via a separate DC source 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 source 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.
6) Brake size B140 may only be operated with a GE module or with an overexcitation factor of 2 with a GS module up to a brake torque of 37 Nm.
Motor rated current Module Part no.
IN≤4 A
SE
260 864 84
IN≤16 A 260 870 84
IN≤50 A 260 896 84
5.2.1 Brake power consumption
400 V AC (180 V DC) supply voltage, control with brake modules
Temperature range: -20 °C to +60 °C
Size Excitation with GE, GF or GP
module
Excitation with GS module
Overexcitation factor of 2
Excitation with GS module
Overexcitation factor of 2,5
I / A
Release current
I / A
Holding current
I / A
Release current
I / A
Holding current
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 6) 0,25 0,50 0,25 0,63 0,25
B280
Operation not permitted.
1,13 0,45
B680 1,80 0,71
•The release and holding currents are identical with normal excitation.
•Release currents for excitation with a GS module are applied for approx. 300 ms.

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Separate brake control with 24 V DC, temperature range: -20 °C to +60 °C
Size Power consumption I / A
B003 0,98
B007 0,90
B020 1,19
B050 1,75
B140 1) 1,73
Depending on the type of connection, the release and braking operation of B003
to B680 DC brakes can generally be characterised by the following values:
5.2.2 Electric connection, brake
actuation times
ZBA/ZBE/ZBP motor brake actuation times
ZBF motor brake actuation times
1) Brake size B140 may only be operated up to a brake torque of 37 Nm.
2) For ZBF travel motors fitted with the B003 as standard, the B007 is used for the manual brake release and/or brake monitoring options.
3) Definition: The brake release time is the period which elapses until the full motor acceleration torque is attained.
Size Release times [ms] Application times [ms]
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
B280 – 140 300 90 130
B680 – 140 300 150 190
Size Release times [ms] Application times [ms]
t11 t12 t21 t22 t23
B003 75 60 175 55 75
B007 2) 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) 3)
t12= brake release time with high-speed excitation (GS) 3)
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 a GS rectifier on ZBA, ZBE and ZBP motors.
Brake application times are highly dependent on the way in which the brake is
connected.

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The coil circuit is interrupted when the brake module contact opens at the relevant
terminal. The magnetic field rapidly decreases and the brake torque rapidly
rises. The rectifiers are protected against overvoltage at the switching contact by
varistors.
Interruption of the DC circuit between the module and the coil connections is not
permitted.
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.
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
compared 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 applications.
• Connection in the DC circuit:
• Connection in the AC circuit:
• Connection in the motor circuit:
1) Definition: The brake release time is the period which elapses until the full motor acceleration torque is attained.
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.
IMPORTANT. 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 applications.
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