document 09 793 67 US

Operating Instructions sheet 1 (7)

Motors and Brakemotors
Type BM (G) Brakes date B / 06.06.00

General conditions must be stated including speed, direction

Every SEW-Eurodrive motor is thoroughly tested, of rotation, position, magnitude and direction of the
checked, and properly packed prior to shipment. external radial and axial loads being applied.
However, please check immediately upon arrival for
shortage of parts or transit damage. Note the dam- Long Term Storage
age or shortage on the freight bill of lading and file If the motor must be stored for a long period of time
a claim with the carrier. Also, notify SEW-Eurodrive without operating, the motor must be stored in a
of the shortage or damage. dry, protected area, and in the mounting position
indicated on the unit nameplate. In order to ensure
Installation that the motor has not been damaged by moisture
For motors mounted integrally to a gear unit, please after a prolonged storage, the insulation resistance
refer to the Operating Instructions for Gearmotors should be checked. An insulation tester with a mea-
and Gear Reducers for proper installation of the surement voltage of at least 500V (e.g. magneto gen-
drive. The drive installation site should be selected erator) should be used for this purpose. The insula-
to ensure: tion resistance is sufficient if it has an ohmic value of
• Ambient temperatures below 40˚C (104˚F). at least 1000 x VN (e.g. at VN = 230VAC: Rinsul > 23000
• Unimpeded flow of air to the motor and variable ohms = 0.23M ohms). If the measured value is small-
speed units. er, the motor should be dried before use (for exam-
• Accessibility to gear unit, oil plugs. ple, with hot air up to a maximum of 90˚C or by resis-
• Adequate space for the removal of the tance heating with an auxiliary AC voltage of 10% of
brakemotor fanguard for brake adjustment VN via an insolating transformer). Care should be
and maintenance. taken to ensure that the motor is heated with not
more than 20% of its rated current and that the rise
The drive unit should be mounted on a flat, vibration in temperature is not more than 90˚C. The drying
damping, and torsionally rigid structure. The flatness procedure can be stopped when the insulation resis-
tolerance of the supporting surface should not tance has reached 500000 = 0.5M ohms.
exceed:
Severe Duty Units
For motor size 180 and smaller — 0.004 inch Severe Duty Units are indicated with the letters “-KS”
For motor size above 180 — 0.008 inch at the end of the motor type on the motor name-
plate. Severe Duty units include drain holes in the
Do not hammer on the shafts to install couplings, motor end belts and conduit box at the lowest points
sheaves, etc. Hammering can cause brinelling of the allowing condensation to drain out of the motor.
bearings and a reduction in bearing life. We recom-
mend heating the components to approximately 175 CAUTION! The drain holes are installed for the
F and sliding them on. This will reduce possible dam- mounting position listed on the gearbox nameplate.
age to the bearings. In addition, there is a metric Installing a unit in a mounting position other than
tapped hole in the center of the motor shaft that can what is shown on the nameplate will reposition the
be utilized with a tool to press on or remove the condensation drain holes. As a result, the drain
coupling, sheaves, etc. holes may not be located at the lowest point and
may not allow water to drain. This can cause pre-
The motor shaft diameters are metric and have toler- mature drive failure.
ances as listed in the SEW-Eurodrive catalogs. Shaft
couplings should be properly aligned to prevent Electrical Connection
vibration, coupling wear and premature failure of The motor must be installed and connected by a
the shaft bearings. qualified electrician who is knowledgeable with the
NEC article 430 and local regulations. He must make
Maximum Parallel Offset — 0.003 inch sure that the voltage and frequency of the electrical
Maximum Angular Offset — 0.030˚ supply correspond with the data stamped on the
motor nameplate before connecting the motor in
To prevent the output shaft and bearings from being accordance with the wiring diagram, which can be
subjected to excessive loads, the maximum overhung found in the terminal box. For brake connections,
loads, as shown in SEW-Eurodrive catalogs, should see the following pages.
not be exceeded. Please consult our engineering
department if the load may exceed the recommend- At installation the electrician must make sure that
ed figure given or where there are combined radial the terminal block jumpers are positioned correctly
and axial loads. In such cases, the exact operating and that all electrical connections including the
 document 01 805 42 US

Operating Instructions sheet 2 (7)

Motors and Brakemotors
Type BM (G) Brakes date B / 06.06.00
Brake Coil Resistance

Motor Frame DT71-80 DT80 DT90-100 DT100 DV112-132S DV132M-160M DV160L-225

Brake Size BM(G)05 BM(G)1 BM(G)2 BM(G)4 BM(G)8 BM15 BM30/31/32/62
Brake Torque (lb-ft) 0.89 - 3.7 4.4 - 7.4 3.7 - 14.8 17.7 - 29.5 7.00 - 55.3 18.4 - 110.6 36.9 - 442.5
BRAKE VOLTAGE RB (Ω) RB (Ω) RB (Ω) RB (Ω) RB (Ω) RB (Ω) RB (Ω)
AC (to rectifier VB) DC RT (Ω) RT (Ω) RT (Ω) RT (Ω) RT (Ω) RT (Ω) RT (Ω)
4.3 3.8 3.3 2.7 1.6 0.8 0.7
— 24
13.2 11.8 10.3 8.2 8.2 5.0 5.3
17.1 15.2 13.3 10.7 6.2 3.1 2.8
105-116 48
52.5 47.0 40.9 32.7 32.7 20.1 21.1
54.0 48.1 42.1 33.8 19.6 9.8 8.9
186-207 80
166 149 129 103 103 63.5 66.7
68.0 60.5 53.0 42.5 24.7 12.4 11.2
208-233 96
209 187 163 130 130 80.8 84.0
171 152 133 107 62 31.1 28.1
330-369 147
525 470 409 327 327 201 211
215 191 168 134 78.1 39.2 35.4
370-414 167
661 591 515 411 411 253 266
271 241 211 169 98.3 49.3 44.6
415-464 185
832 744 649 518 518 318 334
Voltage AC - The voltage shown is the nameplate AC brake voltage supplied to the brake rectifier.
DC - The voltage shown is the effective DC voltage required by the brake coil. The measured
voltage from the rectifier will be 10-20% lower than that shown.
Brake Coil Resistance - values must be measured with the brake coil disconnected from the rectifier.
RB - Accelerator coil resistance inΩ , measured from the red to the white brake coil wire.
RT - Fractional coil resistance inΩ , measured from the white to the blue brake coil wire.

ground connection are secure. In order to effectively This operating instruction covers AC brake voltages
protect the motor from overloads, appropriate motor with the following brake control components. If the
protection must be provided. Fuses do not always brake voltage is DC, or if the brake control components
provide adequate motor protection. For motors differ from those listed below, an additional operating
which are required to operate with a very high start- instruction must be consulted for connection informa-
stop frequency, the overload heater type motor pro- tion.
tection is insufficient. It is advisable in such applica-
tions to provide the motor with temperature sensors SEW-Eurodrive fail-safe mechanical brakes are DC con-
(thermistors) in the windings. Monitor the thermis- trolled. Standardly, a brake rectifier (halfwave) is pro-
tors by means of an external trip device. In this way, vided to convert the AC line voltage to the DC voltage
the motor will be fully protected against practically required to drive the brake. 24VDC brakes do not
all possible overloads. include a rectifier. When voltage (VB) is applied to the
brake, it will release. When voltage (VB) is removed
When using motors outdoors or in washdown appli-
cations the cable entries into the terminal box must Brake Control (Rectifier) Part Number
be directed downward to prevent water from enter- BG1.5 825 384 6
ing the conduit box. The unused cable entries must BG3.0 825 386 2
be closed off properly. BGE1.5 825 385 4
BGE3.0 825 387 0
Lubrication and Maintenance
The motor bearings are sealed and the grease con- from the brake, it will set. The brake rectifier can be
tent is adequate for the life of the bearing. wired either for normal brake reaction time (setting,
stopping) or fast brake reaction time. The fast brake
Brake Connection (AC Voltage) reaction time will set the brake more quickly which will
SEW-Eurodrive motor brakes can be connected in a provide a shorter and more repeatable stopping dis-
number of different ways. In order to connect the tance. There are two basic types of brake rectifiers, BG
brake for each application, it is important to refer to and BGE. The BG brake rectifier is standard on motor
the data on the motor nameplate that describes the sizes DT71 - DT100. The BGE rectifier is standard on
brake system. The brake fields are: brake voltage, motor sizes DV112 - DV225. The BGE rectifier can be
brake torque and brake control. ordered with motor sizes DT71 - DT100 and will pro-
vide faster brake release times allowing the motor to
cycle more frequently.
 document 01 805 42 US

Operating Instructions sheet 3 (7)

Motors and Brakemotors
Type BM (G) Brakes date B / 06.06.00

terminal block, meaning that when power is applied to

the motor it will simultaneously release the brake and
start the motor. See Page 3 for this description.

Brake Voltage Supplied from the Motor

There are specific instances when the brake voltage can
be tapped from the motor’s terminal block. The advan-
tage of brake systems wired in this way is when power
is applied to the motor, the brake releases (requiring
no additional brake supply power wiring). The brake
can be wired to the motor terminal block under the
following conditions: a single speed motor; the motor
is started and run across the line (i.e., no inverter or
The wiring diagrams for brake connections are located electronic soft start). The connections shown on this
on the inside of the motor conduit box lid. The brake page are for normal brake reaction time. For rapid
will release and allow the motor to rotate when the brake reaction time, incorporate the contact as shown
nameplate AC brake voltage VB is supplied to the brake on the brake diagram located on the inside of the
rectifier terminals. There are certain cases where the motor conduit box lid.
brake rectifier can receive its voltage from the motor’s

Brake Motor Connection

Single Speed Dual Voltage-∆∆/∆
- Connection Diagram DT72
Example Motor Voltages:
230∆∆/460∆ Volts - 60 Hz

Motor wired for low voltage. Motor wired for high voltage. Motor wired for high voltage.
Brake voltage matches low Brake voltage matches low Brake voltage matches high
motor voltage. motor voltage. motor voltage.
Example: 230/460V Motor Example: 230/460V Motor Example: 230/460V Motor
Motor wired 230V Motor wired 460V Motor wired 460V
Brake voltage 230V Brake voltage 230V Brake voltage 460V

Brake Motor Connection

Single Speed Dual Voltage - YY/Y
Connection Diagram DT79
Example Motor Voltages:
230YY/460Y Volts - 60 Hz
200YY/400Y Volts - 50 Hz

Motor wired for low voltage. Motor wired for high voltage. Motor wired for high voltage.
Brake voltage matches low Brake voltage matches low Brake voltage matches high
motor voltage. motor voltage. motor voltage.
Example: 230/460V Motor Example: 230/460V Motor Example: 230/460V Motor
Motor wired 230V Motor wired 460V Motor wired 460V
Brake voltage 230V Brake voltage 230V Brake voltage 460V
 document 01 805 42 US

Operating Instructions sheet 4 (7)

Motors and Brakemotors
Type BM (G) Brakes date B / 06.06.00

Brake Motor Connection

Single Speed Dual Voltage - ∆/Y
Connection Diagram DT13
Examples Motor Voltages:
200∆/346Y Volts - 60 Hz
330∆/575Y Volts - 60 Hz
220∆/380Y Volts - 50 Hz

Motor wired for low voltage. Motor wired for high voltage. Motor wired for high voltage.
Brake voltage matches low Brake voltage matches low Brake voltage matches high
motor voltage. motor voltage. motor voltage.
Example: 200/346V Motor Example: 220/380V Motor Example: 220/380V Motor
Motor wired 200V Motor wired 380V Motor wired 380V
Brake voltage 200V Brake voltage 220V Brake voltage 380V

Re-Adjusting the Brake Air Gap Motor Size Brake Size Min. Disc (26) Thickness
A properly adjusted brake air gap is critical for correct DT71 - DT100 BM05 - BM4 0.354” (9mm)
operation. The following table indicates the required DV112 - DV225 BM8 - BM62 0.394” (10mm)
air gap measurement.
If the brake disc (26) is worn below the measurement
Motor Size Brake Size Air Gap
given, it must be replaced. If the thickness is greater
DT71 - DT100 BM(G)05 - BM(G)4 0.010”-0.024” (0.25-0.6 mm)
than the specification above, the brake disc is still
DV112 - DV225 BM(G)8 - BM31 0.012”-0.047” (0.3-1.2 mm)
usable and the brake can be re-adjusted.
BM32 - BM62
DV180 - DV225 0.016”-0.047” (0.4-1.2 mm)
Double Disc
The Hand Release Mechanism
Prolonged use of the brake will wear the brake disc lin- Most of our brakes are supplied with a hand-operated
ing. This wear increases the air gap. When the air gap release lever. This allows opening of the brake without
approaches its maximum value, the brake must be re- applying power, allowing for adjustments on the driven
adjusted. To re-adjust the brake, follow the procedure machinery.
below.
There are two brake release mechanisms available:
1. Remove the fan cover (14), fan snapring, fan (17),
rubber seal (2), and any accessories at the fan end. The “BMHR” (4) type requires a lever to be inserted
2. Insert a feeler gauge between the brake coil body into the release arm. To open the brake, pull the lever
(21) and the stationary disc (22), tighten the adjust- away from the motor. It will re-engage automatically,
ing nuts (19) until the minimum value for the air once the lever is released. The lever, when not used, is
gap is reached equally around the brake. With attached to the motor’s cooling fins with clamps.
motor size 160L and up (brakes BM30 to BM62) first
screw the threaded bushings (24) into the endshield. The screw-type “BMHF” (5) arrangement requires a
After set-ting the air gap, lock the bushings (24) hexagon key which, when turned clockwise, opens the
against the coil body. brake.
3. Ensure a play of 0.06” to 0.08” (1.5 to 2 mm) in the
releasing arm. See “THE HAND RELEASE MECHA- Since the stationary disc (22) will move away from the
NISM.” coil body during the brake’s operation, it is vital that
there is free play (floating clearance) on the release
Replacement of the Brake Disc (26) arm of 0.060”-0.080” (1.5-2.0 mm). The springs (11)
Extended operation of the brake may wear the brake should be placed between the arm (7) and the nuts (12)
disc (26) beyond acceptable limits. The thickness of the to eliminate noise.
brake disc can be measured to determine if this has
occurred. The brake release mechanism is not used to change the
brake’s torque setting. There must always be clear-
ance on the lever.
 document ZU.TSE.01e

Operating Instructions sheet 5 (7)

Motors and Brakemotors
Type BM (G) Brakes date B / 08.04.97

Troubleshooting If the results of all these checks (electrical connec-

Fault: Motor does not run tion, mechanical checks and adjustments, and electri-
1. Check the motor and brake wiring for damage cal tests) indicate that the brake should work, then
and proper connection. the most likely cause of the brakeís failure to release
2. At the motor, measure the line voltage, line cur- is a damaged brake rectifier.
rent and motor resistance of all three phases.
3. If all three phases read a similar current value the Fault: Brake stopping time is too slow
following conditions may exist: If the brake has been operating well for some time
and a gradual increase in stopping time has occurred,
• The motor may be blocked by either an excessive the release arm may have come in contact with the
external load, or problems in the reducer of the coil body. Verify that the brake release arm end play
brake. In both cases, the motor should draw is correct, and check for excessive brake disc wear,
locked rotor (in-rush) current. Consult SEW- (see previous instructions).
Eurodrive catalogs for these values. Release the
brake mechanically, reset the air gap if needed, If the brake has been in operation for some time,
or disconnect the load from the output shaft. and the stopping has become erratic, dust accumula-
tion around the stationary disc guides may be the
• If the brake is at fault electrically see #4 below. cause. Remove the brakeís rubber sealing collar and
clean with an air hose.
• If the current differs significantly from the rated
locked motor current, the motor is either an If the application is new, check the brakeís wiring
incorrect voltage, or it is jumped for the wrong and air gap. If the brake is not wired for fast
voltage. response, then changing the brake wiring to fast
response will decrease the stopping time. Vertical
4. If the brake can be released mechanically, but motion and indexing applications may also require
does not respond to voltage, check the brake for the fast response connection. Increasing the brakeís
electrical problems. torque may remedy the situation, but will also
increase stress on the transmission.
• Make sure the wiring is according to the instruc-
tions. Pay special attention to the brake volt- On applications requiring excessive brake work, the
age. lining’s surface may become glazed due to extreme
heat. The application of a BGE rectifier will improve
• Energize the brake circuit and measure the AC this situation dramatically. BGE rectifiers are stan-
voltage on the rectifier terminals 2 and 3 dard equipment on motors size DV112 - DV225, but
(BG/BGE rectifiers). The measured voltage optional on the smaller sizes DT71 - DT100. Contact
should correspond to the nameplate inscription: SEW-Eurodrive for more information
“Brake V.”

• Measure the DC voltage across terminals 3 and 5

of the brake rectifier which should be about
35% to 45% of the previously measured AC volt-
age.

• If there is no fault found to this point, measure

the resistance of the brake coils. Disconnect the
coil from the rectifier for this measurement. See
the table on Page 2 for the brake coil resistance
values.

• Measure the resistance of each brake coil lead to

the brake coil body. This test should show an
open circuit. If a short is found, the brake coil is
damaged.
 document ZU.TSE.01e

Operating Instructions sheet 6 (7)

Motors and Brakemotors
Type BM (G) Brakes date B / 08.04.97

BM(G) Brake Cross Section and Exploded Views

BM(G) 05 - BM 15 BM 30/31 BM 32/62

(1) Brake end shield (16) Dowel pin

(2) Rubber sealing collar (17) Fan
(3) Braking springs (18) N/A
(4) Hand release lever (19) Brake adjustment nut
(5) Releasing screw (20) Retaining stud
(6) Closing plate (21) Brake coil body
(7) Release arm (22) Stationary disc
(9) Sealing ring (23) Pressure ring
(10) V-ring (24) Setting sleeve
(11) Conical spring (25) Dual brake pad stationary disc
(12) Release (26) Brake disc complete
(13) Stud (27) Carrier
(14) Fanguard (29) Cup Spring
(15) Grommet

Exploded view of the BM and BMG single-disk brake (motor sizes 71-160M)

BM05 - BM15 and BMG05 - BMG8

Exploded view of the BM single-disk and double-disk brake (motor sizes 160L-225)

BM30 - BM62
 document ZU.TSE.01e

Operating Instructions sheet 7 (7)

Motors and Brakemotors
Type BM (G) Brakes date B / 08.04.97

PROBLEM CAUSE REMEDY

Motor not connected for proper supply Check connection diagram on conduit box
voltage cover and correct the wiring.
Supply voltage varies outside the allowable
tolerance causing an undervoltage or over-
Assure correct supply voltage.
voltage condition.
Insufficient cooling air volume due to: Increase air flow:
a. Low frequency operation on variable fre-
a. Continuous running auxiliary fan.
Motor Overheats quency drive.
b. Obstructed air flow. b. Ensure unobstructed air flow.
(Check temperature with
Ensure cool air gets to the motor. Ducting
instrumentation) Ambient temperature is too high.
may be required.
Overload at rated voltage. Unit will draw
current in excess of nameplate rating and run Select a larger unit.
below rated speed.
The problem may or may not be solved
Motor’s allowable duty cycle is exceeded (too
many starts per hour required). with a larger motor. Contact SEW-
Eurodrive.
Single phasing due to break or loose connec- Repair supply lines.
tion in supply line or blown fuse. Replace fuses.
Determine and correct cause of failure
Blown fuse.
and replace fuse.
Reset protective device. Identify and cor-
Motor does not run. Motor protection device activated.
rect cause for device activation.
Motor protection device faulty or will not
reset.
Check protection device for faults.

Motor not connected for proper voltage. Check connection diagram in conduit box
Motor will not start or starts cover and correct the wiring.
sluggishly. Large voltage and/or frequency fluctuation at Ensure stable power supply.
starting.
For reduced voltage starting, Start motor directly in Delta Connection if
motor will not start in Star Insufficient torque in Star Connection.
possible. Otherwise use a larger motor.
Connection but will start in
Delta Connection. Faulty contact in Star/Delta starter. Correct fault condition.
Motor hums and draws high Faulty or defective winding. Have motor repaired by qualified service
current. Rotor dragging. shop.
Short circuit in power supply conductors or in Correct the fault condition.
the motor.
Fuses blow or motor overcurrent Motor has ground fault or winding to Have motor repaired by qualified service
protection trips immediately. winding short circuit. shop.
Check connection diagram in conduit box
Motor improperly connected.
cover and correct the wiring.
Motor runs in wrong direction. Motor supply leads misconnected. Switch two supply leads.
Note: If after proceeding through the Troubleshooting Chart the motor is found to be defective, contact your nearest
SEW-Eurodrive Assembly Plant for warranty assistance or replacement parts.

SOUTHEAST MANUFACTURING EAST COAST ASSEMBLY CENTER

& ASSEMBLY CENTER 200 High Hill Road/Bridgeport NJ 08014
1295 Spartanburg Highway/Lyman SC 29365 (609) 467-2277 Fax: (609) 845-3179
(864) 439-7537 Fax: (864) 439-7830
WEST COAST ASSEMBLY CENTER
SOUTHWEST ASSEMBLY CENTER 30599 San Antonio Road/Hayward CA 94544
3950 Platinum Way/Dallas TX 75237 (510) 487-3560 Fax: (510) 487-6381
(214) 330-4824 Fax: (214) 330-4724

MIDWEST ASSEMBLY CENTER

2001 West Main Street/Troy OH 45373
(937) 335-0036 Fax: (937) 222-4104