The Y2EJ series electromagnetic brake of three-phase asynchronous motors
( special used in quick cable-releasing equip )
1. Abstract
1.1 The features of products
This series of motor is the common three-phrase asynchronous motor with complete-closed, self-refrigeration and squirrel cage. It is characterized by high-efficiency, economical, high start torque, low noises, small vibratuon and easy maitain. The motor crust’s protection level is IP54, the solenoid brake’s is IP23, the Frame number is H80-355, the strcucture and the base installation type is IMB3，IMB5，IMB35.The voltage rating of solenoid brake have two type: AC and DC, you can choice one of it according to you need.(remarks: solenoid brake)
1.2 Main application and range of application
The Y2 series can be used in the common situations, the YEJ2 series can be used many kinds machine which need stop quickly, accurate positioning, reciprocating operation and deslick.
1.3 environmental condition of use
1. There should be no acidic gas, alkalinous gas and others can corrode conductor’s insulator.
2. Height above sea level: lower than 1000m
3. Environmental temperature: from -15℃ to 40℃
1.4 Running conditions
1. Voltage rating: 380V, Nominal power: 50Hz
2. Running mode: S1 (sequential). You should reduce the working time when it need continually to start, and the numbers of start should less than 1 time every 2 second if the load is over 70%; but when the load is below 70%, the numbers is less than 1 time per second.
3. Connection: star connection (smaller or equal to 3kw), delta connection (more than or equal to 4kw).
The motor is made up of three basic parts: stator (stationary part), rotor (rotating part) and solenoid brake. After the motor’s stator winding is connected to three-phrase power, the brake’s magnet coil is electrified (the direct voltage is supplied to the coil by rectifier). The coil can cause the magnetic field and pull the anchor towards magnetic wheel, so the anchor brake away from the disc-braked. At the same time, there cause the revolving magnetic field in the space of stator. Then there has induced electromotive force in the conductor because the relative moving between the rotor and revolving magnetic field. The torque in the rotating shaft which produced by the electromagnetic force can make the rotor rotating. When the stator winding is power-down, the brake’s magnet coil is power-down. So the magnetic energy is released and the spring presses on the anchor. (制动盘上的摩擦轮压紧) The friction pulley on the magnetic wheel compress and braked by the friction force.
3. Preparatory work before installation
3.1 Check visually if the packing box of motor are intact or be affected with damp before open it;
3.2 Carefully check the data on the nameplate;
3.3 Carefully check whether there have damage, deformation, loosing or fall off of fastening piece and flexibility of the motor’s shaft or not. For the electromagnetic braking motor, the shaft can rotate before the manual tripping device is moved or rotated.
3.4 When measuring the insulating resistance by 500MΩ ohmmeter, the value is not below 0.5MΩ. If not, it must to dry the winding, but its temperature is not exceed 120℃。
4. The motor’s mounting 4.1 The motor’s transfer motion can use coupler, spur gear or belt pulley. But for the 2-pole and 4KW or 4-pole and 11KW motors, they can not use belt pulley. If selecting small pulley, it can enlarge transmission range of texrope. For the biaxial extension motor, its fan end only can use coupler to transmit. 4.2 When use belt to transmit, the axes of motor’s shaft and assorted shaft are parallel and the axes of belt and shaft are vertical. When using coupler to transmit, the center lines of motor and assorted shaft are superposition. 4.3 For the vertical mounting motor, there has no any other thrust load device except pulley( or equal to a common pulley load) on the shaft extension. 4.4 The mounting of motor should ensure that there has good ventilation and cooling.
4.5 Can use manual method to mounting the electromagnetic braking motor. The relief device is electromagnet. ( ，释放装置使电磁铁。制电螺栓插入电机风罩端轴孔，) (止动螺栓) Inserting the retainer bolt into the hole which lie in the shaft end of motor’s fan housing and clockwise rotating it, so the brake is off-position. Rotating the motor’s shaft and making install easily. After contrarotate bolt and make it loose, the brake is on-position.
5. Operation of motor
5.1 The motor must be adequately grounded, the earthing device lie in lower right of junction box. If it is necessarily you can use the motor’s bottom or the flange’s standing bolt to ground. 5.2 There are six post heads on patching board. They are marked as follows:
Phase sequence A B C head U1 V1 W1 end U2 V2 W2 5.3 Selecting star connection or delta connection according to the nameplate.
5.4 The motor usually has thermal protection device. You should adjust its setting according to the name-plate current.
5.5 The motor can’t output rated power if the value of power frequency deviate nameplate’s over 1% or the voltage deviate over 5%. The motor must not overload if it is continuous working. 5.6 When the motor work, there shouldn’t have intermittent or unusual noise or vibration. The bearing’s temperature is not up to 950℃. 5.7 When the motor start, the voltage must be full value and the current is 5-7 times rating current. 5.8 Operation and notices:
①After started the motor, there have not abnormal phenomenon in motor, spin gearing, actuator, line voltage and ammeter, otherwise the motor should be stopped. Again to start the motor after trouble cleared.
②After power on, , the motor must be stop if it can’t work, that can avoid to damage the motor.
③ In according to the motor’s technique requirement, the sequential starting times are limited in 3-5(unload) or 2-3(extended service and heat). If not, the motor is easy to be damage. ④ The motors can’t be started as the same time if they are use a same transformer, but they can be started from high-power to low power. ⑤The brake must be work in oilless because it is dry-type, that can avoid to effect the torque. ⑥After using the brake for a while, if the air gap(δ) exceed the maximal allowable value because the wear of friction plate, it should be take-down, cleared and readjusted to prescribed value. See the table 1:
Frame number
Working air gapδ
the maximal allowable value ofδ
YEJ280
0.3
1.0
YEJ290-100
0.4
YEJ2112
0.5
YEJ2132
0.5
1.2
YEJ2160-180
0.6
YEJ2200-225
0.8
1.5
YEJ2250-355
0.8
⑦Before mounting the brake, the bolt should be adjusted to the specified air gap (δ), then back-out the hollow stay bolt and to compact the motor’s back cap or bracket’s back face.
☆ Happening electric shock accidents;
☆ The motor or starter smoke or fire;
☆ The motor is strenuous vibrating;
☆ The motor’s actuator is damaged;
☆ The motor’s bearing is hot;
☆ When happened some things in the motor, for example, axial float, stator scrapping rotor, speed suddenly dropped, temperature shoot up and so on.
5.9 Diagnosis and Elimination The common fault and its clearing is lie in table 2.
Table 2 The common fault and its clearing in using motor
Fault symptom
Ananlysis of cause
Clearing methods
can’tstart
1. power off
2. the fault of stator winding
3. over loading or spin gearing is stucked
4.false connection of control appliance
5.controller is not be release
6.the fault of rectifier
checking switch, fuse element, all touch spots and lead-out wires and finding fault;
professional checking whether winding is open circuit, short circuit and grounding or not, and repaired.
selecting high power motor or lighten load. Checking the machine if the spin gearing is stucked and to clear it.
correcting connection
correcting brak’s connection, checking air gap and brake;
renewal rectifier;
The speed lower the rating when the motor running with load
1.power-line voltage is too low
2.the load is overlarge;
3.the brake’s anchor is not depart from the magnetic wheel.
1. checking the power-line voltage of input end by voltmeter, multimeter.
2. selecting high-power motor and lighten load;
3. adjusting the air gap.
Grounding is invalid and the motor’s crust is electriferous
mistaking the power line and earth line
the motor’s winding is be affected with damp, insulated, aging or colliding between connecting plate and lead-out line.
1. correcting earth line;
2. drying the winding, change the winding when there are serious insulate and aging, adjusting the earth line
The running voice is abnormal
1. there have friction between rotor and stator or felt paper;
2. running with open-phase
3. the bearing is damage or oilless.
1.checking if there have prominency on the felt paper or the wrong running of bearing, and repairing it.
2.checking switch, fuse element, contactor and connection and so on, and clearing all the fault;
3.change or clear the bearing, change lubricant.
The motor is vibrating.
1. the dynamic balance of rotor is disqualification.
2.the bore on belt pulley is offcenter or static balance is disqualification;
3.shaft extension is bending;
4. the foot is loosen.
1.correcting the rotor’s dynamic balance;
2.to amend offcenter and correct static balance;
3.aligning or changing.
4.fasten the stone bolt.
bearing running hot
1. the bearing is damage;
2.poor quality or inappropriate fill of bearing grease;
3. the belt is tension or the coupler’s mounting is incorrect;
4. the bearing or shaft is badly damaged and deform;
5. the motor’s two end closure or bearing cap is installed incorrectly.
1. change the bearing;
2. changing bearing grease, and the grease fill represents not more than 70% of the space in the bearing;
3. adjusting the belt’s tension and correcting coupler;
4. repairing worn parts by bush fitting or coating;
5. to correctly install the end closure and bearing cap, and tighten the bolt or screw.
the motor can’t brake
the working air-gap of brake exceeds the permitted value
readjust the working air-gap to the permitted value
6. installing protector and trouble removal The protection’s level of this series motor is IP5, its cooling method is IC0141:
The motor should be properly grounding and there must have earthing device in the junction box. In case of necessity, its grounding can be achieved by trip bolt.
The motor should have thermel protection device and adjust the rating value according to the motor nameplate current. 当电动机的热保护及短路连续发生动作。
7. Maintaining and repairing of motor
7.1 Operating ambient should be kept dry, the motor’s surface should be kept clean, inlet opening should not be blocked by dust or fiber or others. After checking source of trouble, the motor comes into operating.
7.2 small maintenance item: ① Measuring insulation resistance after cleaning dust on motor;
② Checking and cleaning wire connecting terminal of motor;
③ Checking its fastness, such as bolt, screw or earth wire;
④ Checking the noise and lubricant of bearing;
⑤ Checking and cleaning starter and its insulation resistance;
⑥ Checking if the air gap value beyond the limits.
7.3 big maintenance item: ① all the small maintenance item;
② Checking and cleaning inside the motor, trimming stator winding and making it orderly, non-oily, non-exposed, no short circuit inside coil of wire or phrase, no earthing and so on. Checking end ring and molybdenum bar of rotor, overhauling magnet core of stator and rotor.
③ Ensuring good lubricant when the motor is running. Usually, when the motor run for 2500 hours, it should be replenished or replaced grease lubricant.(close type bearing in life-time needn’t to replace grease lubricant).It should replace grease lubricant in time when the bearing overheating or lubricant is abnormal. When do this, the original grease lubricant should be cleaned out, bearing and oil sink in bearing cap should be washed out by gasoline, then filling the gap between the bearing ‘s inner ring and outer ring with ZL-3 lithium grease.
When changing the grease lubricant, you should clean up the old one , wash bearing and oil groove in bearing cover in gasoline, then fill the ZL-3 lithium grease into the cavum between the inner and outer rings of bearing, the quantity is 1/2(2-pole) or 2/3(4-pole) of the volume.
④Regular or irregular to maintenance of electromagnetic brakes
☆When the thickness of braking disc less than 1mm,it must be changed.
☆Clean up all the parts of brake and ensure there are no sundries on working face.
☆Ensure the brake disc and hub splines can be moved.
☆It must adjust the δ value when the brake can’t proper functioning because the normal wear cause big δ. The method is loosing the hollow adjustment screw and adjusting construction bolt to make the δ within the specified range (see the following form). Then lock-in the hollow screw and make the electromagnet normal functioning.
⑤ When the vibration and noise of motor will be significantly larger, please check the bearing radial clearance. If the value approach the following values, the bearing must be changed.
bearing inside diameter（mm）
20-30
35-50
55-50
80-120
Limit wear windage（mm）
0.10
0.15
0.20
0.30
⑥ When dismantle the motor, it must avoid damage the stator winding or insulator.
⑦ When changing the winding, you must mark down its style, size, turn number and wire size. If you lose them, you must obtained them form the manufacturer and can’t change the original design because it can effect the motor’s function or make the motor failure.
8.The connection method of DC brake with rectifier is showed in Fig.1 9.related data of brake (Fig.2)
K----- normally open contact Caution:
When it leaves the factory, the motor’s “K” is being short-circuit (the DC output terminal of certifier is connected to brake), the equipment is slow application. If the user need it to quick-acting, the mode of connection must according to Fig.1, the braking time might have been 0.1s.
Mounting dimensions
Frame number
Radial length
Axial length
d1
d2
d3
d4
d5
h1
h2
Φ
μ
e
L
L1
L2
L3
δ
H80
118
105
90
65
3-M5
124
79
19.8
22.6
6
20
50
27
3.5
0.3
H90
128
114
98
65
3-M6
126
81
24.8
28.1
8
25
58
34
3.5
0.4
H100
148
133
116
76
3-M6
134
91
29.5
32.8
8
30
61
36
3
0.4
H112
166
150
131
90
3-M8
162
104
29.5
32.8
8
30
64
41
3
0.5
H132
187
170
151
104
3-M8
175
113
39.5
42.8
12
30
75
48
3
0.5
H160
222
202
180
128
4-M10
232
138
44.5
47.8
12
35
88
56
4
0.6
H180
265
244
220
165
4-M10
49
52.8
14
40
3.5
H200
305
280
255
195
4-M12
59
63.4
18
50
115
3.5
0.8
H225
325
300
268
210
4-M12
59
63.4
18
50
120
3.5
0.8
H250
400
360
315
240
4-M16
65
69.4
18
50
120
3.5
0.8
H280
432
400
360
280
4-M16
69
73.4
18
50
120
3.5
0.8
H315
560
520
480
395
4-M16
80
85.4
22
50
125
4
0.8
H355
660
610
560
480
4-M20
95
100.4
25
50
130
4
0.8
Caution:
1. The value of δ is normal working gap.
2. There is no method of AC brake’s mounting, details see the manufacturer’s announcement.
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