Demag DR rope hoist

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Demag DR rope hoist Powered By Docstoc
					Demag DR rope hoist
without electrical control




                             42576444.eps                               42349444.eps




                                                         42352044.eps




081105 EN                                   203 640 44                        714 IS 813
    Manufacturer                             Demag Cranes & Components GmbH
                                             P.O. Box 67, D-58286 Wetter
                                             Telephone (+49 2335) 92-0 · Telefax (+49 2335) 927676
                                             www.demagcranes.com




                                             Please fill in the following table before first putting the hoist into service.
                                             This provides you with a definitive documentation of your Demag rope hoist
                                             and important information if you ever have to contact the manufacturer or his
                                             representative.


                                             Owner

                                             Where in use

                                             Range

                                             Serial number

                                             Main hoist motor number

                                             Operating voltage

                                             Control voltage

                                             Frequency

                                             Wiring diagram number




    Further documents
    Operating instructions
    Demag rope hoist FDR 3 - FDR 5- FDR 10 (PRO)                                                        214 932 44             720 IS 813
    Demag rope hoist EKDR 3 - EKDR 5- EKDR 10 (PRO)                                                     214 725 44             720 IS 813
    Demag rope hoist EZDR 5- EZDR 10 (PRO)                                                              214 961 44             720 IS 813
    Demag rope hoist FDR 3 - FDR 5- FDR 10 (COM)                                                        214 990 44             720 IS 813
    Demag rope hoist EKDR 3 - EKDR 5- EKDR 10 (COM                                                      214 916 44             720 IS 813
    Demag rope hoist EZDR 5- EZDR 10 (COM)                                                              214 965 44             720 IS 813


    Dedrive Compact DIC                                                                                 214 708 44             720 IS 922
                                                                                                                                            20364044.p65/081105




    CD Dedrive Compact DIC                                                                              213 137 44             716 IS 922
    External pulse generator                                                                            214 372 44             720 IS 919
    Z motor range                                                                                       214 228 44             720 IS 919
2
                      Introduction




                                     This document contains information on rope hoists without electrical control. It ap-
                                     plies for DR-Pro, EKDR-Pro, EZDR-Pro, FDR-Pro, EKDR-Com, EZDR-Com, FDR-
                                     Com rope hoists.

                                     Depending on the type, the standard scope of delivery includes:

                                     - 12/2-pole hoist motor with Microtherm and EG integrated pulse generator
                                     - GS and VE brake modules
                                     - 4-pole hoist motor with Microtherm and mechanical mounting device for AG 1 - 3
                                       external pulse generators
                                     - GS and VE brake modules
                                     - 4-pole cross travel motor with Microtherm
                                     - GE and VE brake modules
                                     - Base plate in the rope hoist electrical enclosure for connecting the hoist motor and
                                       sensors
                                     - SGG geared limit switch
                                     - SGS overload cut-out
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                                                                                                                              3
    Design overview




      Example of EKDR                                                                  Travel motor
                                                                                                             EKDR low-headroom monorail hoist
             Thrust rocker


             Electrical equipment cover
             with terminal strip and
             geared limit switch




                                                                                                                     Gearbox with hoist motor



                 4/1 bottom block




    Fig. 1                                                                                                                                                   42577844.eps



    Explanation of size designation / type assignment
    EK DR - Pro 3 - 3,2 4/1 - 6 Z - 6/1 - 400 - 00 - 50 - 30 300 45
                                                                                                                       Rail head width in mm

                                                                                                                       or track gauge in mm         }  Only for EZDR


                                                                                                                       Flange width of the girder in mm

                                                                                                                       or girder section and size (IPE240)

                                                                                                                       Maximum cross-travel speed in m/min

                                                                                                                       Frequency [Hz]

                                                                                                                       Electrical equipment code 1)

                                                                                                                       Operating voltage [ V ]

                                                                                                                       Hoist speed in m/min

                                                                                                                       Motor type: Z = Cylindrical rotor

                                                                                                                       Hook path in m

                                                                                                                       Reeving

                                                                                                                       SWL in t

                                                                                                                       Range 3; 5; 10

                                                                                                                       Demag rope hoist

                                                                                                                       K = Low-headroom monorail hoist
                                                                                                                       Z = Crab
                                                                                                                       F = Stationary

                                                                                                                      E = Electric travel trolley
    1) Code 00    DR without electrical control
       Code 01    EKDR with internal electrics for application on a crane. Crane bridge enclosure, DSE-8R control pendant with control cable and cables for the
                                                                                                                                                                            20364044.p65/081105




                  mobile floor control must be ordered separately.
       Code 02    FDR/EKDR/EZDR with internal electrics and solo electrics with crane switch and transformer fitted in an enclosure on the trolley, for application as a
                  solo trolley. DSE-8R control pendant with control cable must be ordered separately.
       Code 03    Like code 01 but control via radio control system
       Code 04    Like code 02 but control via radio control system
4      Code 05    EKDR with fitted parallel interface “in”
                      Selection criteria
                      DR-Pro F-/EKDR 3 - F-/EK-/EZDR 5, 10
                      The size of the hoist is determined by the load            1.   What are the operating conditions?                          5. Do the loads need to be lifted and lowered with
                      spectrum, average operating time per working day,          2.   What is the specified safe working load?                       high precision?
                      SWL and reeving.                                           3.   To what height must the load be lifted?                     6. Is horizontal load travel necessary?
                                                                                 4.   What is the required lifting speed?                         7. How is the hoist to be controlled?
                      The load spectrum
                      (in most cases estimated) can be evaluated in
                                                                                 The group is determined from the operating time and load spectrum
                      accordance with the following definitions:
                                                                                 Load spectrum                                               Average operating time per day in hours
                      1 Light
                      Hoist units which are usually subject to very small        1                   Light                                   4-8                  8-16                    over 16
                      loads and in exceptional cases only to maximum             2                   Medium                                  2-4                  4-8                     8-16
                      loads.
                                                                                 3                   Heavy                                   1-2                  2-4                     4-8

                                                                                 4                   Very heavy                              0,5-1                1-2                     2-4
                                          Small partial load
                                                                                                                          FEM                2m                   3m                      4m
                                          Small dead load
                        SWL




                                                                                 Group of mechanisms to
                                                                                                                          ISO                M5                   M6                      M7
                           Operating time
                      2 Medium
                                                                                 Group of
                      Hoist units which are usually subject to small loads
                                                                                 mechanisms            2 m/M 5 3 m/M 6 4 m/M 7 2 m/M 5 3 m/M 6 4 m/M 7 2 m/M 5 3 m/M7 4 m/M 7
                      but rather often to maximum loads.
                                                                                 FEM/ISO 1)
                                                                                                                           2)                                                                       2)
                                                                                 Rope reeving                   2/1, 4/2                                4/1                               6/1
                                       Heavy partial load                        Range                                                               SWL in t
                                       Medium partial load
                                                                                 DR 5                    2,5         2          1,6          5             4       3,2          -               -                -
                                       Medium dead load
                       SWL




                                                                                 DR 10                      5        4          3,2          10            8       6,3         16           12,5                 -
                              Operating time

                      3 Heavy                                                    Example
                      Hoist units which are usually subject to medium            SWL                                                  5t
                      loads but frequently to maximum loads.
                                                                                 Load spectrum                                        “medium” from table
                                                                                 Hoist speed                                          6 m/min
                                          Heavy dead load                        Creep hoist speed                                    1 m/min
                                                                                 Reeving                                              4/1
                        SWL




                                                                                 Average hook path                                    3m
                               Operating time
                                                                                 No. of cycles/hour                                   20
                      4 Very heavy                                               Working time/day                                     8 hours
                      Hoist units which are usually subject to maximum or
                      almost maximum loads.
                                                                                 The average operating time per working day is estimated or calculated as follows:
                                                                                                      2 x average hook path x no. of cycles/h x working time/day
                                     Very heavy dead load                        Operating time/day =
                                                                                                                           60 x lifting speed
                                                                                                      2 x 3 x 20 x 8
                                                                                 Operating time/day =                = 2,66 hours
                                                                                                          60 x 6
                       SWL




                              Operating time                                     For the “medium” load spectrum and an average daily operating time of 2,66 hours,
                                                                                 the table shows group 2 m. For a load capacity of 5 t and 4/1 rope reeving, the table
                                                                                 indicates hoist size DR 5 - 5.
                      Selection table
                      Range             Group of               SWL    Hook path                Lifting speed m/min                    SWL          Hook path               Lifting speed m/min
                                      mechanisms to             t            m           V1            V2            V3                t               m            V1               V2                     V3
                                        FEM/ISO
                                                                                       2/1                                                                        4/1
                                         2 m/M 5               1,6                                                                    3,2
                      F-/EK-
                                         3 m/M 6               1,25     12; 20          12/2          18/3       2-25 3)              2,5             6; 10         6/1             9/1,5                1-12,5 3)
                      DR 3
                                         4 m/M 7                1                                                                      2

                                         2 m/M 5               2,5                                                                     5
                      F-/EK-/EZ-
                                         3 m/M 6                2       12; 20          12/2          18/3       2-25 3)               4              6; 10         6/1             9/1,5                1-12,5 3)
                      DR 5
                                         4 m/M 7               1,6                                                                    3,2

                                         2 m/M 5                5                                                                     10

                                         3 m/M 6                4       12; 20         10/1,7       2-18 3)      2-25 3)               8              6; 10        5/0,8            1-9 3)               1-12,5 3)

                                         4 m/M 7               3,2                                                                    6,3
                      F-/EK-/EZ-
                                                                                       4/2                                                                       6/1 4)
                      DR 10
                                         2 m/M 5                5                                                                     16
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                                                                      5,8; 11,35;
                                         3 m/M 6                4                      10/1,7       2-18 3)      2-25 3)              12,5          6,7; 13,3     2,7/0,4           0,7-6                    -
                                                                         15,2
                                         4 m/M 7               3,2                                                                    10


                                                                                 1) Gearbox service life 20 % above the FEM value                 3) for 87 Hz delta operation
                                                                                 2) 4/2 and 6/1 rope reeving only for DR 10                       4) 6/1 rope reeving only for EZDR 10                               5
    DR-Com F-/EKDR 3 - F-/EK-/EZDR 5, 10
    The size of the hoist is determined by the load        1.   What are the operating conditions?                   5. Do the loads need to be lifted and lowered with
    spectrum, average operating time per working day,      2.   What is the specified safe working load?                high precision?
    SWL and reeving.                                       3.   To what height must the load be lifted?              6. Is horizontal load travel necessary?
                                                           4.   What is the required lifting speed?                  7. How is the hoist to be controlled?

    The load spectrum                                      The group is determined from the operating time and load spectrum
    (in most cases estimated) can be evaluated in
    accordance with the following definitions:                                                                                                    Average operating time
                                                           Load spectrum
                                                                                                                                                  per day in hours

    1 Light                                                1                           Light                                                                 2-4
    Hoist units which are usually subject to very small
    loads and in exceptional cases only to maximum         2                           Medium                                                                1-2
    loads.
                                                           3                           Heavy                                                                0,5-1

                                                           4                            Very heavy                                                        up to 0,5
                        Small partial load
                        Small dead load
      SWL




                                                                                                                    FEM                                     1 Am
                                                           Group of mechanisms to
         Operating time
    2 Medium
                                                                                                                    ISO                                     M4

    Hoist units which are usually subject to small loads
    but rather often to maximum loads.                     Group of mechanisms to FEM/ISO 1)                                           1 Am/M 4

                                                           Rope reeving arrangement                                                          4/1
                     Heavy partial load
                     Medium partial load                   Range                                                                          SWL in t
                     Medium dead load
     SWL




                                                           DR 3                                                                              3,2

            Operating time                                 DR 5                                                                              5

    3 Heavy                                                DR 10                                                                             10
    Hoist units which are usually subject to medium
    loads but frequently to maximum loads.
                                                           Example
                                                           SWL                                             5t
                        Heavy dead load                    Load spectrum                                   “medium” from table
                                                           Hoist speed                                     4.5 m/min
      SWL




                                                           Creep hoist speed                               0,8 m/min
             Operating time
                                                           Reeving                                         4/1
    4 Very heavy                                           Average hook path                               3m
    Hoist units which are usually subject to maximum or
    almost maximum loads.
                                                           No. of cycles/hour                              10
                                                           Working time/day                                8 hours
                   Very heavy dead load
                                                           The average operating time per working day is estimated or calculated as follows:
                                                                                         2 x average hook path x no. of cycles/h x working time/day
                                                            Operating time/day =
                                                                                                             60 x lifting speed
     SWL




                                                                                         2 x 3 x 10 x 8
            Operating time                                  Operating time/day =                        = 17 hours
                                                                                                           ,
                                                                                            60 x 4,5
                                                           For the “medium” load spectrum and an average daily operating time of 1,7 hours,
                                                           the table shows group 1 Am . For a load capacity of 5 t and 4/1 rope reeving, the
                                                           table indicates hoist size DR 5 - 5.

    Selection table                                        Range                  Group of mechanisms         SWL                 Hook path               Lifting speed
                                                                                           to                                                                  m/min
                                                                                        FEM/ISO                 t                     m                        V1

                                                                                                                                       4/1

                                                                                                                2

                                                           F-/EKDR 3                                           2,5                  6; 10                    4,5/0,8

                                                                                                               3,2

                                                                                                               4
                                                           F-/EK-/EZDR 5                1 Am/M 4                                    6; 10                    4,5/0,8
                                                                                                               5
                                                                                                                                                                           20364044.p65/081105




                                                                                                               6,3

                                                           F-/EK-/EZDR 10                                      8                    6; 10                     4/0,7

                                                                                                               10


6                                                          1) Gearbox service life 20 % above the FEM value
20364044.p65/081105




7
    Key data pole-changing hoist drives DR 3 – DR 5 – DR 10
    Design is in accordance with the VDE regulations and the design rules of the FEM, to meet the high demands made on
    electric hoists.




    Main/creep lifting F6                            Required supply cable conductor cross sections and fuse links
    Range DR 3       No. of   Code        P           % CDF         n        Starts/h      Rated current IN and starting current IA         cos         cos
                     poles                                                                                for 50 Hz
                                                                                                                 400 V                      ϕN           ϕA
    Motor size                           kW                       rpm                             IN (A)                     IA (A)

    ZBR 100           12                0,55            20        430          240                 4,6                         7            0,53        0,72
                               V1
    C 12/2 - B050      2                 3,4            40        2800         120                 8,5                        40            0,78        0,88

    ZBR 100           12                 0,8            20        4 10         240                 5,7                         9            0,55        0,75
                               V2
    D 12/2 - B050      2                 5,3            40        2780         120                 11                         55            0,88        0,85



                              Mains connection delay fuse for 50 Hz 1)                  Supply lines for 5% voltage drop ∆U and starting current IA for 50 Hz 2)
    Range DR 3
                                                400 V                                                                     400 V (∆U 20 V)

    Motor size                                   A                                                       mm²                                      m

    ZBR 100 C 12/2                               20                                                        1,5                                    25

    ZBR 100 D 12/2                               25                                                        1,5                                    19


    Range DR 5       No. of   Code        P           % CDF             n       Starts/h     Rated current IN and starting current IA       cos         cos
                     poles                                                                                  for 50 Hz
                                                                                                                  400 V                     ϕN          ϕA
    Motor size                           kW                          rpm                            IN (A)                   IA (A)

    ZBR 100           12                  0,8            20          410          240                5,7                       9            0,55        0,75
                               V1
    D 12/2 - B050      2                  5,3            40         2780          120                11                       55            0,88        0,85

    ZBR 132           12                  1,4            20          400          240                9,6                       15           0,54        0,68
                               V2
    D 12/2 - B140      2                  8,9            40         2870          120                18                       120           0,89        0,85



                              Mains connection delay fuse for 50 Hz 1)                  Supply lines for 5% voltage drop ∆U and starting current IA for 50 Hz 2)
    Range DR 5
                                                400 V                                                                     400 V (∆U 20 V)

    Motor size                                   A                                                       mm²                                      m

    ZBR 100 D 12/2                               25                                                        1,5                                    19

    ZBR 132 D 12/2                               50                                                        2,5                                    15


    Range DR 10      No. of   Code        P           % CDF             n      Starts/h     Rated current IN and starting current IA        cos         cos
                     poles                                                                                 for 50 Hz
                                                                                                                  400 V                     ϕN          ϕA
    Motor size                           kW                         rpm                            IN (A)                    IA (A)

    ZBR 132            12                1,4            20          400          240                9,6                       15            0,54        0,68
                               V1
    D 12/2 - B140      2                 8,9            40         2870          120                 18                       120           0,89        0,85




                              Mains connection delay fuse for 50 Hz 1)                  Supply lines for 5% voltage drop ∆U and starting current IA for 50 Hz 2)
    Range DR 10
                                                400 V                                                                     400 V (∆U 20 V)

    Motor size                                   A                                                       mm²                                      m

    ZBR 132 D 12/2                               50                                                        2,5                                    15
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                                                     1) Fuse links also apply in conjunction with a cross travel motor.
8                                                    2) The lengths of the supply lines are calculated on the basis of an earth-loop impedance of 200 mΩ.
                      Key data cross travel drives DR 3 – DR 5 – DR 10




                      The cross travel drives of the DR without electrical control are designed for operation with a Demag frequency inverter in the
                      120 Hz range. We recommend that Demag DIC Dedrive Compact frequency inverters be used. Owing to the large input voltage
                      range of the Dedrive Compact, the DR without electrical control can be operated with mains voltages of 380...480 V with
                      50...60 Hz. At 380 V, the max. frequency must be reduced by 5 Hz.


                      Key data of inverter-controlled cross travel drive DR 3, DR 5, DR 10 - 2/1 - 4/1 - 4/2
                      Range DR 3-10           No. of poles         %CDF            Output       Current         cos ϕ             n      Recommended
                                                                                     P          at 220 V                     for 50 Hz    inverter type

                      Motor size                                                    kW            I (A)                           rpm    Dedrive Compact

                      ZBA 71 B4 - B003             4                60              0,37          2,6           0,54           1375       DIC-4-004-E




                      Key data of inverter-controlled cross travel drive EZDR 10 -Pro 6/1
                      Range DR 10             No. of poles         %CDF            Output       Current         cos ϕ             n      Recommended
                                                                                     P          at 220 V                     for 50 Hz    inverter type

                      Motor size                                                    kW            I (A)                           rpm    Dedrive Compact

                      ZBA 90 A4 - B007             4                60              1,1           5,1           0,74           1400       DIC-4-007-E




                      Example for calculating the cross sec-         ZBR 100 C 2/12, 400 V required length 25 m
                      tions of the conductors of cables ex-              Known cross section x required length 2,5 x 25
                      ceeding the length indicated in the table:                                              =         = 4 mm2
                                                                                Known cable length               16
20364044.p65/081105




                                                                                                                                                           9
     Key data of inverter-operated hoist drives DR 3, DR 5, DR 10
     Design is in accordance with the VDE regulations and the design rules of the FEM, to meet the high demands made on
     electric hoists.




     The hoist drives of the DR without electrical control are designed for operation with a Demag frequency inverter in the 87 Hz
     range. We recommend that Demag DIC Dedrive Compact frequency inverters be used. Owing to the large input voltage range of
     the Dedrive Compact, the DR without electrical control can be operated with mains voltages of 380...480 V with 50...60 Hz. At
     380 V, the max. frequency must be reduced by 5 Hz.


     Range DR 3           No. of poles      Code      FEM classification      % CDF        Output       Current        cos ϕ            n               Recommended
                                                                                             P          at 220 V                   for 50 Hz             inverter type

     Motor size                                                                              kW              I (A)                     rpm          Dedrive Compact

     ZBR 100 B 4 - B050                                        2m                                                                                         DIC-4-017

     ZBR 100 B 4 - B050        4              V3               3m              60            4,2             16,9       0,85           1350               DIC-4-014

     ZBR 100 B 4 - B050                                        4m                                                                                         DIC-4-014



     Range DR 3                    Mains connection delay fuse for 50 Hz 1)                               Supply lines for 5% voltage drop ∆U 2)

                                                    400 V                                                            400 V (∆U 20 V)

     Inverter type                                    A                                               mm²                                          m

     DIC-4-017                                       16                                                1,5                                         58

     DIC-4-014                                       16                                                1,5                                         70




     Range DR 5           No. of poles      Code      FEM classification      % CDF        Output       Current        cos ϕ            n               Recommended
                                                                                             P          at 220 V                   for 50 Hz             inverter type

     Motor size                                                                              kW              I (A)                     rpm          Dedrive Compact

     ZBR 132 B 4 - B140                                        2m                            8,3             29,0       0,87           1420               DIC-4-025

     ZBR 112 A 4 - B140        4              V3               3m              60                                                                         DIC-4-025
                                                                                             5,3             18,7       0,84           1430
     ZBR 112 A 4 - B140                                        4m                                                                                         DIC-4-017



     Range DR 5                    Mains connection delay fuse for 50 Hz 1)                               Supply lines for 5% voltage drop ∆U 2)

                                                    400 V                                                            400 V (∆U 20 V)

     Inverter type                                    A                                               mm²                                          m

     DIC-4-025                                       35                                                2,5                                         65

     DIC-4-017                                       16                                                1,5                                         58



     Range DR 10          No. of poles      Code      FEM classification      % CDF        Output       Current        cos ϕ            n               Recommended
                                                                                             P          at 220 V                   for 50 Hz             inverter type

     Motor size                                                                              kW              I (A)                     rpm          Dedrive Compact

     ZBR 132 C 4 - B140                                        2m                           10,2          38,0          0,84           1425               DIC-4-040

     ZBR 132 B 4 - B140                      V2                3m              60                                                                         DIC-4-032
                                                                                             8,3          29,0          0,87           1420
     ZBR 132 B 4 - B140                                        4m                                                                                         DIC-4-025
                               4
     ZBR 132 C 4 - B140                                        2m              50           13,1          46,5          0,83           1410               DIC-4-040

     ZBR 132 C 4 - B140                      V3                3m                                                                                         DIC-4-040
                                                                               60           10,2          38,0          0,84           1425
     ZBR 132 C 4 - B140                                        4m                                                                                         DIC-4-032


     Range DR 10                   Mains connection delay fuse for 50 Hz 1)                               Supply lines for 5% voltage drop ∆U 2)

                                                    400 V                                                            400 V (∆U 20 V)

     Inverter type                                    A                                               mm²                                          m

     DIC-4-040                                       50                                                6,0                                         97
                                                                                                                                                                         20364044.p65/081105




     DIC-4-032                                       35                                                4,0                                         80

     DIC-4-025                                       35                                                2,5                                         65


                                                          1) Fuse links also apply in conjunction with a cross travel motor.
10                                                        2) The lengths of the supply lines are calculated on the basis of an earth-loop impedance of 200 mΩ.
                      Parameter settings for recommended Demag DIC Dedrive Compact frequency inverter




                      Please refer to the table below for the required parameter settings.
                      For the hoist drives, rotary encoder feedback on the motor is required. We recommend that the Demag AG 2 external pulse gen-
                      erator be used together with the EM-ENC-02 extension module for the Demag Dedrive Compact frequency inverter.
                      After entry of the rated motor values, it is absolutely necessary to perform parameter identification.




                      No.    Name                              Unit                   ZBA                                               ZBR
                                                                              71 B4         90 A4         100 B4        112 A4          132 B4              132 C4
                                                                                                           60%                                      50%              60%
                      030    Configuration                      -                     410                                                210

                      370    Rated voltage                      V                                                        220

                      371    Rated current                      A              2,6            5,1          16,9          18,7            29,0       46,5             38,0

                      372    Rated speed                       rpm            1375          1400           1350          1430           1420        1410             1425

                      373    No. of pole pairs                  -                                                          2

                      374    Rated cosine phi                   -              0,54          0,74          0,85          0,84            0,87       0,83             0,84

                      375    Rated frequency                   Hz                                                         50

                      376    Mech. rated output                kW              0,4            1,1          4,2            5,3            8,3        13,1             10,2



                      417    Frequency switch-off limit        Hz                     250                                                100

                      418    Min. frequency                    Hz                      5                                                  8

                      419    Max. frequency 1)                 Hz                     120                   84                   85                          86

                      420     Acceleration                     Hz/s                    25                   42                   42,5                        43

                      421    Deceleration                      Hz/s                    50                   42                   42,5                        43



                      490    Operating mode encoder 1           -                      0                                                  4
                             Pulse number per revolution of
                      491                                       -                      -                                 Depending on rotary encoder used
                             encoder 1


                      721     Amplification speed controller    -                      3                                                 10
                             Integral action time speed
                      722                                      ms                     200                                                100
                             controller


                      For further details regarding commissioning, the many control possibilities, the various hoist functions and the selection of further
                      additional components of the DIC Dedrive Compact, refer to the operating instructions 214 708 44 and 214 716 44. The permis-
                      sible ambient conditions must be complied with.
20364044.p65/081105




                                                                      1) At 380 V, the max. frequency must be reduced by 5 Hz.                                              11
12
                  Fig. 2
                                                          1



                                                                                             Top-hat rail, 200 mm long




                                                                                                                                                                                                                                                    5
                                                                                                                                                                                                                                 PE
                                                                                                                                                                                                      J
                                                                                                                                                                           EG
                                                                                                                                                                                                                PE
                                                                                                                                                              1 2 3 4 5 6
                                                                                     3                                                      4
                                            2                          2 pol. HUB
                                                                      2-pole hoist
                                                                                                                                                          12VE     A   1A        B       1B   GDNE


                                     12-pole HUB
                                      12 pol. hoist
                                                                                                                                                                                                               PE         PE              PE
                                                                                                   6          7           8          9
                                                                                                                                                                           X52
                                                                                                                                                      L                                       10 K 11                                               12

                                       U    V         W           U            V         W
                                                                                                                                           SGS                         SGG                                     Kreuz1
                                                                                                                                                                                                               Cross1              Cross2
                                                                                                                                                                                                                                   Kreuz2

                                                                                                                                     1     2 PE 1         2    3       4    5        6        7   8       1    2     3 PE 1           2   3 PE




                                                                                             ThH       ThH   Brg   Brg   BrH   BrH   SGS SGS    PE SGG1SGG2 SGG3SGG4 SGG5 SGG6 SGG7 SGG8                  X161 X162 X163 PE   X418 X482 X483   PE
                                                X11




                                                      A                                                                              X53                                   X5                                  X16              X48
                                                                          X9                                                                         PE                                                                                             PE
                                                                                                                                                                                                                                                         Connection plate with terminal strip for DR with 2-/12-pole hoist




                                                              B                              C                                       D           E                 F                                          G                H               I




                      42354944.eps
20364044.p65/081105
                      Customer connections
                      1   Top-hat rail
                      2   12-pole hoist motor connection
                      3   2-pole hoist motor connection
                      4   EG integrated pulse generator
                      5   Protective earth conductor PE
                      6   Thermo-switch hoist motor
                      7   Brake release contact hoist motor
                      8   Brake hoist motor
                      9   SGS overload protective device, electro-mechanical
                      10 SGG geared limit switch
                      11 Cross travel cut-out system, general
                      12 Cross travel cut-out system, preliminary (v2 → v1)



                      All terminals must be connected with up to 4 mm² Cu cross section, except
                      2-pole hoist and PE which must be connected with up to 16 mm² Cu cross
                      section.



                      Factory connections

                      A   Terminal X11 (12-pole hoist motor)
                      B   Terminal X9 (2-pole hoist motor)
                      C   Terminal X10 (signals hoist motor)
                      D   Terminal X53 (SGS)
                      E   Protective earth conductor PE
                      F   Terminal X5 (SGG)
                      G   Terminal X16 (cut-out)
                      H   Terminal X48 (prel.)
                      I   Protective earth conductor PE
                      J   Protective earth conductor PE
                      K   Protective earth conductor PE
                      L   Connection X52 (integrated pulse generator hoist motor)
20364044.p65/081105




                                                                                                  13
14
                      Fig. 3
                                                          1



                                                                                              Top-hat rail, 200 mm long




                                                                                                                                                                                                                                                 5
                                                                                                                                                                                                                              PE
                                                                                                                                                                                                   J
                                                                                                                                                                        EG
                                                                                                                                                                                                             PE
                                                                                                                                                           1 2 3 4 5 6
                                                                                  3                                                      4
                                            2                         2 pol. hoist
                                                                      2-poleHUB
                                                                                                                                                       12VE     A   1A        B       1B   GDNE


                                     12-pole HUB
                                      12 pol. hoist
                                                                                                                                                                                                            PE         PE              PE
                                                                                                6          7           8          9
                                                                                                                                                                        X52
                                                                                                                                                   L                                       10 K 11                                               12

                                        U   V         W           U           V       W                                                                                                                      Cross1                Cross2
                                                                                                                                        SGS                         SGG                                      Kreuz1                Kreuz2

                                                                                                                                  1     2 PE 1         2    3       4    5        6        7   8       1    2     3 PE 1           2   3 PE




                                                                                          ThH       ThH   Brg   Brg   BrH   BrH   SGS SGS    PE SGG1SGG2 SGG3SGG4 SGG5 SGG6 SGG7 SGG8                  X161 X162 X163 PE   X418 X482 X483   PE
                                                X11




                                                      A                                                                           X53                                   X5                                  X16              X48
                                                                         X9                                                                       PE                                                                                             PE




                                                              B                           C                                       D           E                 F                                          G                H               I
                                                                                                                                                                                                                                                      Connection plate with terminal strip for DR with 4-pole hoist motor




                      42356144.eps
20364044.p65/081105
                      Customer connections
                      For the DR with 4-pole hoist motor, the connection is made directly in the motor
                      terminal box

                      1   Top-hat rail
                      2   -
                      3   -
                      4   -
                      5   Protective earth conductor PE
                      6   -
                      7   -
                      8   -
                      9   SGS overload protective device, electro-mechanical
                      10 SGG geared limit switch
                      11 Cross travel cut-out system, general
                      12 Cross travel cut-out system, preliminary (v2 → v1)

                      All terminals must be connected with up to 4 mm² Cu cross section, except
                      2-pole hoist and PE which must be connected with up to 16 mm² Cu cross
                      section.


                      Factory connections

                      A   Terminal X11 (12-pole hoist motor)
                      B   Terminal X9 (2-pole hoist motor)
                      C   Terminal X10 (signals hoist motor)
                      D   Terminal X53 (SGS)
                      E   Protective earth conductor PE
                      F   Terminal X5 (SGG)
                      G   Terminal X16 (cut-out)
                      H   Terminal X48 (prel.)
                      I   Protective earth conductor PE
                      J   Protective earth conductor PE
                      K   Protective earth conductor PE
                      L   Connection X52 (integrated pulse generator hoist motor)
20364044.p65/081105




                                                                                                         15
     Cable unions




         DR 3 cable unions                                      DR 5 cable unions
                                    2                                                                             2




     1                                                      1




                                                                                                          3
                              3

                                         42355044.eps
                                                                                                                          42355144.eps




         DR 10 cable unions                                     Cable unions, DR 3, DR 5, DR 10 cover
                                     2




     1


                                                                                                                                   4




                              3


     Fig. 4                               42355244.eps                                                                    42355344.eps



                                  1 Round cable union M251)
                                  2 Round cable union M201)
                                  3 Twist-type cable entry gland for cable glands up to max. 12,5 mm
                                  4 Round cable union M25
                                                                                                                                         20364044.p65/081105




                                  1) Screw-type unions must have long threads (approx. 15 mm)
                                     e.g. cable union Schlemmer-Tec,                   manufacturer no. 5307620 (M20 x 1,5)
16                                        cable union Schlemmer-Tec,                   manufacturer no. 5307125 (M25 x 1,5)
                      Connection diagrams




                      Hoist motor connection diagrams
                       Pole-changing hoist drive                                                                                                                                                       ZBR 100 motor terminal block

                                                                                                                                                                                                 Y/Y
                                                                                                                                                                                                                                                                                                                    U                                4           2       1

                                                            CW          CCW                                                                                                                                                                                                                                                                           wh gn bn
                               1L1 1L2 1L3                                                                                    2L1 2L2 2L3                                                                                                                                                                   SP1 SP2               TB1     TB2
                                                                                                                                                                                                                                                                                                                                                    1S3 1S2 1S1

                                                                                                                                                                                                       1U         1V           1W              2U             2V             2W              BD1 BD2
                                                                                                                                                                                                       T1         T2           T3              T11            T12            T13


                                                                                                                                                                                                              U        U       U                     U           U       U
                                                                                                                                            Re-start block min.
                                                                                                                                            250 ms!                                                     1SP1 1SP2 1SP3                        2SP1 2SP2 2SP3




                                                                                                                                                                                                                      1U           1V           1W               2U              2V           2W      BD1           BD2           TB1 TB2 1S3 1S2 1S1
                                                                                                                                                                                                                      T1           T2           T3               T11             T12          T13     SP1           SP2
                                                                                                                                                                                                                      1SP1         1SP2         1SP3             2SP1            2SP2         2SP3




                      low                                         high
                                                                                                                                        GS                                                                        1L1          1L2            1L3            1L1*            1L2*           1L3*           L+               1L-
                      speed                                       speed                                 VE                                  7   ~
                                                                                                                                            6   ~
                                                                                                 RD                  BU WH                  5   ~                                                                                                                                                                                                                             41003284.eps
                                                                                                                                            4
                                                                                                                                            3
                                                                                                                                            2   -                                                      ZBR 132 motor terminal block
                                                                                                                       X1                   1   +           PCB in DR
                                                                  Switchgear
                                                                  cabinet                                                                                                                        Y/D                                                             2V
                                                                                                                                                     TB1
                                                                                                                                                                      TB2
                                                                                                                                                                      1S2
                                                                                                                                                                                           1S1




                                                                                                         RD                                                                                                                                                      T12
                                                                                                                                                                                                                                                                                                                        U                                4           2        1

                                                                    Motor                                                                                                                                                                                                                                       SP1 SP2            TB1     TB2
                                                                                                                                                                                                                                                                                                                                                       wh gn bn
                                                                                                                                                                                                                                                                                                                                                     1S3 1S2 1S1
                                                                                                                             U                                                                                                            2U                                          2W
                                                                                                                                                                                                                                                                                              BD1 BD2
                                                                                                                                                                                                       1U             1V           1W     T11                                         T13
                                        U       U       U
                                                                                                                                                                                                       T1             T2           T3



                                            1V                                                    BD2                      BD1                                                                                    U        U       U                     U           U       U

                               1U                   1W
                                                                                                                                                      Thermo-switch




                                                                                                                                                                                                            1SP1 1SP2 1SP3                      2SP1 2SP2 2SP3
                                                                                                                                                                        Brake monitoring




                       PE            M
                                     3~
                               2U                   2W                                                                                                                                                                  1U             1V           1W               2U            2V          2W      BD1              BD2        TB1 TB2 1S3 1S2 1S1
                                            2V                                                                                                                                                                          T1             T2           T3               T11           T12         T13     SP1              SP2
                                                                                                                                                                                                                        1SP1           1SP2         1SP3             2SP1          2SP2        2SP3

                                    U       U       U



                                                                                                                                                                                                                      1L1          1L2         1L3               1L1*            1L2*        1L3*           L+               1L-




                                                                                                                                                    42356044.eps                                                                                                                                                                                                                  41004384.eps



                         Hoist drive with frequency inverter                                                                                                                                       Motor terminal board


                                                             1L1 1L2 1L3                                                          2L1 2L2 2L3
                                                                                                                                                                                                        U2            V2           W2
                                                                                                                                                                                                                                                                  X1

                                                                                                                                                                                                                                                                                                                                                4            2       1
                                                                             Frequency
                                                                             inverter hoist                                                                                                                                                           RD
                                                                                                                                                                                                                                                                                                                    TB1           TB2
                                                                                                                                                                                                                                                                                                                                                 wh          gn          bn

                                                                                                                                                                                                        U1            V1           W1                    VE+ GS1 BD1                         BD1 BD2                                       1S3 1S2 1S1


                                                              ~                                                                                  Re-start block min.
                                                                                                                                                 250 ms!
                                                                                                                                                                                                              W2        U2         V2
                                                                                                                                                                                                                                                                         VE                                                 GS


                                                             U V W
                                                                   ~                                                   Switch-
                                                                                                                                                                                                              U1        V1         W1
                                                                                                                                                                                                                                                                 WH
                                                                                                                                                                                                                                                                                  -
                                                                                                                                                                                                                                                                                   BU RD
                                                                                                                                                                                                                                                                                        +
                                                                                                                                                                                                                                                                                                       7        6       5     4     3
                                                                                                                                                                                                                                                                                                                                  WH BU
                                                                                                                                                                                                                                                                                                                                          -
                                                                                                                                                                                                                                                                                                                                          2
                                                                                                                                                                                                                                                                                                                                                +
                                                                                                                                                                                                                                                                                                                                                1


                                                                                                                                                                                                             1L1 1L2 1L3
                                                                                                                       gear                                                                                                                                  4                   3 X1                 2L3 2L2 2L1                       BD2 X1
                                                                           TB1
                                                                                 TB2
                                                                                 1S2
                                                                                                  1S1




                                                                                                                       cabinet                                                                                                                                       GS
                                                            U1 V1 W1                                                                                                                                                                                                                                                          VE
                                                                                                                                                GS
                                                                                                                       VE                       7    ~
                                                                                                                                                6    ~                 Motor
                                                                                                             RD              BU WH              5    ~
                                                                                                                                                4                      terminal box
                                                                                                                                                3
                                                                                                                        X1                      2    -
                                                                                                                                                1    +

                                                                                                                      RD




                                                                                                                      BD2        BD1

                                    PE                           M
                                                                 3~                                                        Motor
                                                                                 Thermo-switch

                                                                                                  Brake monitoring




                                                            U2
                                                                 V2
                                                                   W2



                      Fig. 5
                                                                                                                                                    42355944.eps                                                                                                                                                                                                              03800784.eps
20364044.p65/081105




                                                                                                                                                                                                                                                                                                                                                                                                 17
     Cross travel motor connection diagram

      Cross-travel drive with frequency inverter                                                                                Motor terminal block



                1L1 1L2 1L3                                               2L1 2L2 2L3
                                                                                                                                                                        U

                                                        Switch-
                                                        gear                                                                                                      SP1       SP2                         TB1   TB2


                                                        cabinet                                                                  U1   V1         W1
                                                                                                                                                                                       BD1     BD2
                                                                                                                                 T1   T2         T3
                                                                                        GE
                 ~                                          VE                          7
                                                                                        6 ~
                      ~                                RD     BU WH
                                                                                        5 ~
                                                                                        4
                                                                                        3
                                                                                        2 -
                                                                 X1                     1 +                                                 U1         V1    W1             BD1        BD2    TB1 TB2
                                                                                                                                            T1         T2    T3             SP1        SP2
                                TB1
                                                TB2




                                                            RD
                                                                                   Motor terminal
                                                                                   block
                                                                         U                                                             L1         L2        L3                    L+     L-




                      V1                                 BD2             BD1
                U1         W1

           PE        M
                     3~
                                      Thermo-switch




                                                      Motor
                                                                 Brake




      Fig. 6                                                                                  42355844.eps                                                                                                          41003384.eps




     EG integrated pulse                                                                      See operating instructions for Motors, type Z, ident. no. 214 228 44
     generator

     Brake release contact                                                                    See operating instructions for Motors, type Z, ident. no. 214 228 44


     Temperature sensor, hoist                                                                See operating instructions for Motors, type Z, ident. no. 214 228 44
     and cross travel motor
                                                                                                                                                                                                                                   20364044.p65/081105




18
                      Brake control




                                      Various control modules are available for controlling Demag B003 to B680 disk
                                      brakes with DC magnets.
                                      All modules can also be fitted inside the switchgear cabinet.
                                      In this case, the brake coil must be protected against switching voltage peaks by
                                      means of a varistor, part no. 260 898 84, in the motor terminal box.
                                      All rectifiers feature varistor protection against overvoltage at the AC input and on the
                                      switching contact terminal as standard.
                                      The braking rectifiers are approved for a max. AC voltage of 500 V AC.
                                      Brake cut-out in the AC or DC circuit is possible with GE rectifiers (cross travel) and
                                      GS rectifiers (hoist) depending on the connection.
                                      Brake application times are highly dependent on the way in which the brake is
                                      switched off.
                                      For the DR without electrical control system, cut-out in the DC circuit by using the
                                      VE module is necessary.

                                      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.



                                      Brake control modules
                                      • GE brake rectifiers (normal excitation)
                                         GE brake rectifiers are used for the cross travel drive of the DR as standard.
                                         They mainly consist of a half-wave rectifier with integrated free-wheeling circuit.
                                      • GS brake rectifiers (high-speed excitation)
                                         GS brake rectifiers are used for the ZBR motors of the DR hoist drives as
                                         standard.
                                         The GS module includes a reversible rectifier which overexcites the brake for ap-
                                         prox. 0,3 seconds to release it and supplies it with the appropriate holding voltage
                                         from a half-wave rectifier (overexcitation factor of 2,5 with 3-phase connection).

                                         Important: When used with a pole-changing motor, GS modules must always
                                                    be provided with a separate power supply.

                                         To ensure perfect functioning for cut-out of the GS and VE modules, i.e. switching
                                         with overexcitation, min. 250 ms must expire between cut-out and switching on
                                         again.

                                      • VE voltage relays (voltage-dependent high-speed trip relay)
                                         VE voltage relays can be combined with GE, GS and GP brake rectifiers. VE
                                         voltage relays must only be used for brakes with a separate power supply.
                                         These modules are preferably used for inverter-fed motors. They are used for
                                         high-speed demagnetization of the brake to achieve fast brake application times
                                         without the need for additional wiring for brake cut-out 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.
20364044.p65/081105




                                                                                                                                  19
     SGG geared limit switch




                                     Adjusting screw, black             Adjusting screw, white

                                                                                                                SGG/terminal strip connection

                                                                                                                    SGG     Switch contacts
                                                                                                                    1        1

                                                                                                            1

                                                                                                                    2        2

                                                                                                                    3        3

                                                                                                            2

                                                                                                                    4        4

                                                                                                                    5        5

                                                                                                                3

                                                                                                                    6        6

                                                                                                                    7        7
       For adjusting the geared limit switch, a hexagon socket key, 4 mm, is required.                          4

                                                                                                                    8        8


      Fig. 7                                                                            42589444.eps




     Adjusting instructions for SGG                 Before setting the switching points, make sure that live contacts are provided with a
                                                    touch guard in order to protect them against accidental contact.



                                                    Allow for run-on!



     Operating principle                            Each contact is allocated to a cam disk which is infinitely adjustable.
                                                    The cam disks can be adjusted independently by means of the white adjusting
                                                    screws.

     Adjust                                         When turning the white adjusting screw clockwise, the cam disk is also turned clock-
                                                    wise. The switching point is shifted upwards in accordance with the hook path.
                                                    When turning the screw anti-clockwise, the switching point is shifted downwards.
                                                    Standard cam disks are designed in such a way that a max. useful path and a run-on
                                                    path are available.

     Setting the contacts for individual            The geared limit switch is already permanently connected with the control system via
     adjustment:                                    the system connector cable. For setting the contacts, turn the white adjusting screw
                                                    until the contact maker opens the contact.
                                                    If the run-on path is exceeded, the contact either opens or closes.

     Setting the contacts for adjustment in         The contacts are adjusted in blocks by means of the black adjusting screw. All cam
     blocks:                                        disks are adjusted together, while the relative adjustment of the individual contacts
                                                    remains unchanged. When turning the black adjusting screw clockwise, the cam
                                                    disks are also turned clockwise.



                                                    Approach cut-out points several times to check the limit switch functions are
                                                    operating correctly!
                                                                                                                                                20364044.p65/081105




20
                      Technical data

                      Transmission ratio:                         i = 205 with block setting of all cam disks designed for min. >1x106 switching
                                                                  operations

                      Switch contacts:                            4

                      Contact type:                               Change-over contact, snap-action contact, NC with automatic disconnection,
                                                                  contact material: silver/silver


                      Cam disc:                                   with 15° leading cams

                      Switching point repeat accuracy:            approx. +/-15 mm on hook, least favourable case for 2/1 reeving and hook path
                                                                  12 m. In this case, the 47 revolutions on the drive shaft result in an adjusting angle
                                                                  of 79,71° on the cam shaft for i = 205.

                      Electrical connection:                      Terminal strip direct connection on PCB.
                      Technical features:
                      Compliance with standards                   EN 60204-1             IEC 947-5-1 EN 60947-T5-1
                                                                  EN 60529               EN 50013       IEC 536
                      Ambient temperature                         Continuous operation -40 °C to +80 °C
                      Type of enclosure                           IP 54
                      Insulation class                            Class II
                      Approvals                                   CE and CSA

                      Technical features of
                      switching elements:                         VDE 0660 part 200 from 7/92
                      Positive opening to rated operating volt-   250 V AC and 24/80 V DC
                      age Ui
                      Thermal continuous current Ith              6A
                      Category acc. to VDE 0660:                  AC-15, 230 V AC/1,5 A

                      Mechanical service lives in switching       DC-13, 60 V DC/0,5 A
                      cycles                                      10 x 106 switching operations
                      Terminal identification                     Acc. to EN 50013
                      Approvals                                   CE-UL/CSA
                      Current load to plug connector              6 A / 85 °C 250 V AC
                      Outer dimensions:
                      Length up to pinion cover                   approx. 165 mm
                      Enclosure dimensions                        approx. 91 x 72 mm
                      Overall height                              approx. 95 mm
20364044.p65/081105




                                                                                                                                                           21
     Load detector




     SGS overload cut-out,
     electro-mechanical



                Position switch




                                                                                       Receptacle with tab, 6,3-2.1




                                                                                                 Socket connector, 2-pole




      Fig. 8                                                                                                          42355444.eps




                                  Depending on the design, the SGS overload switch is set to the rated load of the DR
                                  and integrated in the DR hoist. The SGS contact must be evaluated in addition to
                                  avoid any vibration in the system caused by switching off and on again.

                                  We recommend the use of MKA-2 contact evaluators for standard applications.
                                  This unit prevents premature enabling of the lifting motion and the resulting vibration
                                  processes by means of signal filtering. The unit is available for three control voltage
                                  ranges, it is included in the supply depending on the order.

                                  In combination with the SGS, only the ‘overload cut-out’ function can be used.

                                  SGS                           Load link
                                  Input voltage:                          24 V, 9600 Hz
                                  Output signal:                Load limit contact NC -X53
                                  V switching capacity:         4 A/230 V AC; 1 A/24 V DC
                                  Ambient temperature:          -30° C to +80° C
                                  Type of enclosure:            IP 67
                                  Mounting position:            Any
                                                                                                                                     20364044.p65/081105




22
                      MKA-2 front plate/connec-
                      tion diagram/dimensions

                                                        1)




                                A1      13        14         23   24             1) Jumpers for crane acceptance test.
                                                                                    Remove jumpers after acceptance test.



                                   O.K CLK   Dematik ® MKA-2
                                                46953144

                                        MGS
                                  gn    br/ws      ge

                                1        2         3         4    A2
                                                                                 MKA-2 dimensions


                                                                                 MKA-2 front plate



                                                    Overload protec-
                                                    tion
                                                    Position 1 (not




                                                                                                                                                   71
                                                    SGS)
                                                    Position 2
                                                    Overload cut-out




                                                                                               45,0                                113,0
                           Jumper positions
                                                                                                                                                  40995644.eps
                       Fig. 9                                     41873344.eps




                      Dematik® MKA-2 contact evaluator
                      Part no.:                   For control voltage            220...240 V, 50/60 Hz               469 531 44
                                                                                 110...120 V, 50/60 Hz               469 532 44
                                                                                 42...48 V,      50/60 Hz            469 533 44
                                                                                 24 V,           50/60 Hz            469 534 44

                      Other voltages in special designs:
                      Possible contacts:                                         2 NO contacts
                      Rated cut-out capacity:                                    230 V; 5 A AC11, 4 A conditional nominal short-circuit current
                      Operating voltage range:                                   90 to 100 % of the nominal value
                      Nom. consumption:                                          max. 4 VA
                      Ambient temperature range:                                 -20° C to +70° C
                      Mode:                                                      Suitable for continuous operation
                      Type of enclosure:                                         IP 40 to DIN 40050
                      Conductor connection:                                      max. 2 x 2,5 mm² with self-releasing washers
20364044.p65/081105




                      Mounting position:                                         Any
                      Mounting:                                                  Quick mounting for carrier rail 35 mm
                      Weight:                                                    390 g
                                                                                                                                                                 23
     Block wiring diagram




      Dematik® SGS/MKA-2 as overload cut-out

                        L1,L2,L3 PE




                                                                  F2




                                                        K3                 K4




                                                                       M
                                                                      3

                                                                      M2


                   L4

                                 S2              S1
                                                                           A1

                            S1             S2
                                                                 U1    Dematik MKA-2
                                         23
                              U1
                                         24                            A2         2        3
                             S3            S3



                                                                                                         Jumper in position 2
                                                                                                         = Overload cut-out                    Equipment designation
                                  K4             K3
                                                                                                         (see page 23, fig 9)
                                                                           SGS1                   SGS2                                         B1    = SGS limit switch
                              K3              K4
                                                                                                                                               F2    = Fuse ‘main hoist motor’
                                                                                                                                               K3    = Contactor ‘Main lifting’
                                                                                Brown

                                                                                         Yellow




                                                                                                                                               K4    = Contactor ‘Main lowering’
                   L5
                                       Lifting        Lowering                                                                                 M2    = Main hoist motor
                                                                                        SGS
                                                                                                                                               S1/S2 = Pushbutton lifting/lowering
                                                                                    21        22                                               S3    = Emergency limit switch lifting/lowering
                                                                                                                                               U1    = MKA-2 contact evaluator
      Fig. 10                                                                                                                   42356644.eps



     Function: SGS / MKA-2 as overload                                 The SGS load link is plugged into position SGS on the PCB (SGS 1, SGS 2, PE).
     cut-out                                                           The outgoing terminal connections are connected to the MKA-2 contact evaluator.
                                                                       DR terminal SGS 1 on MKA terminal 2 and DR terminal SGS 2 on MKA terminal 3.
                                                                       Plug the jumper behind the front plate of the MKA-2 into position 2, i.e. between the
                                                                       pins in the middle and at the bottom.
                                                                       (see also description of MGS/MKA-2 load detectors (206 689 44))
                                                                       When SGS and MKA are used in combination, only the ‘overload cut-out’ function
                                                                       can be used.
                                                                       Only use contacts 23 - 24 of the MKA.
                                                                                                                                                                                                 20364044.p65/081105




24
                      ZMS, FGB-2, FWL overload protection




                                                                                                                                     FGB-2 with PVC module
                                       ZMS




                                                                                                                                                             Screening over outer sheath




                       Fig. 11                                                                                                                                                          42355544.eps




                      Calculating and setting the
                      overload switching point
                       Rope    FEM          Nominal load [t]         Lever     ZMS                2/1             4/1               6/1            4/2                         LF [x10-3]
                       hoist
                                      2/1      4/1   6/1       4/2   A/B     Nom. load Value S1 to S7 Value S1 to S7 Value S1 to S7 Value S1 to S7                  2/1      4/1       6/1     4/2
                                                                                [t]
                                 2m   1,6     3,2                                            75   1101001   75     1101001                                            1,0596
                       DR 3      3m   1,25    2,5                     0,5      0,625         60   0011110   60    0011110      -          -   -          -            2,2222            -       -
                                 4m    1       2                                             49   1000110   49    1000110                                             4,3403
                                 2m   2,5      5                                             75   1101001   75     1101001                                            1,0596
                       DR 5      3m    2       4                     0,64      1,25          61   1011110   61    1011110      -          -   -          -            2,0696            -       -
                                 4m   1,6     3,2                                            50   0100110   50    0100110                                             4,0422
                                 2m    5       10     16       5                          110 1100111 115 1100111 122 0101111 115 1100111                             0,2778         0,2289 0,2778
                      DR 10      3m    4       8     12,5      4      0,5      1,25          93   1011101   93     1011101 115 1100111        93   1011101            0,5425         0,4800 0,5425
                                 4m   3,2     6,3     10       3,2                           75   1101001   74    0101001     78    0111001   75   1101001 1,0596 1,1109 0,9375              1,0596


                      Calculation example for FWL overload                            Rope hoist                             A/B
                      cut-out                                                         DR 3 and 10                            0,5
                                                                                      DR 5                                   0,64


                      Example:                                                                                      Nominal load x A/B x 110          8 t x 0,5 x 110
                      DR 10-Pro, 8 t in 4/1                                        FWL switch value =                                            +5 =                 + 5 = 93
                                                                                                                 No. of ropes x nominal load ZMS         4 x 1,25 t
                      ZMS = 1,25 t
20364044.p65/081105




                      A/B = 0,5
                                                                                   For a detailed description: see document 206 880 44


                                                                                                                                                                                                       25
     FWL load spectrum recorder




     Application          The service life of hoist units mainly depends on the selection of the appropriate
                          group of mechanisms, i.e. the correct estimation of operating time and load spec-
                          trum. Over long periods of utilization, however, operating conditions may change at
                          a later date which may result in a longer or shorter service life. The conversion from
                          single to double-shift operation for a production crane, for example, results in dou-
                          bling daily utilization and, therefore, results in correspondingly faster wear of the drive
                          mechanisms.
                          Since hoist units are designed for specific periods of operation based on the rules of
                          fatigue strength, failures must be expected after the end of the theoretical service life
                          has been reached.
                          FWL units record all loads on the hoist unit during operation, in a power-failure safe
                          and long-term memory. The load spectrum recorder indicates experienced utilization.
                          It therefore continuously provides information on the operating conditions and the
                          calculated remaining service life of the hoist unit.



     Mode of operation    The load spectrum recorder measures the lifted load and the hoist motor operating
                          period.
                          The measured load is compared with the SWL and a relative load is calculated. Since
                          wear on the moving parts of the hoist unit increases disproportionately with rising
                          load, the value for relative loading is evaluated accordingly. Owing to this evaluation,
                          operation of the hoist unit with half the rated load only creates (1/2)3 = 1/8 of the load
                          spectrum value (LK value) which is reached by operation with rated load.
                          For ¼ rated load, therefore, the LK value is (1/4)3 = 1/64, etc.
                          The operating time of the hoist unit is measured as the duty time of the lifting and
                          lowering motions. Since wear can be assumed proportionally to the operating time,
                          the measured value is integrated as a proportion of time in the displayed LK value.
                          Double the operating time with identical load as a consequence corresponds to a
                          doubled LK value.
                          The load spectrum recorder collects the measured loading of the hoist unit, continu-
                          ously for any load and duty intervals. The LK value therefore corresponds to the sum
                          total of loads experienced so far. In contrast to the elapsed operating time counter, it
                          is not the pure duration of operation of the hoist unit that is displayed but the load on
                          the hoist unit is recorded, which is of far greater importance for wear, and evaluated
                          according to its influence.
                          The counter in the load spectrum recorder is calibrated so that when the strain gauge
                          carrier link is loaded with the SWL in group of mechanisms 1 Bm, the LK value
                          counts +1 per second.
                          This makes the load spectrum recorder an effective instrument for monitoring hoist
                          units.
                          Based on continuous recording of the displayed LK value, in particular in conjunction
                          with maintenance work, the owner of the hoist unit can easily obtain important infor-
                          mation for cost-effective planning of maintenance and preventive maintenance work.
                          It is possible to analyse utilization of hoist units on the basis of the recorded LK values
                          to appropriately plan any extension or modernisation measures.
                          The loading and operating time class to FEM can be verified at any time in conjunc-
                          tion with the elapsed operating time counter.
                                                                                                                        20364044.p65/081105




26
                      Calculation of the elapsed                                                         The FWL load spectrum recorder makes is possible to determine the past duration
                                                                                                         of service and, as a consequence, also the remaining duration of service.
                      safe working period (SWP)
                                                                                                         For measuring, the nominal load of the ZMS is used as the reference nominal load.
                                                                                                         This means that the FWL counts the full load seconds of the ZMS. If the ZMS is not
                                                                                                         to be loaded with its own nominal load (for hoist unit nominal load), the displayed
                                                                                                         value needs to be corrected by a specific factor. This correction factor must be en-
                                                                                                         tered into the crane test and inspection booklet when the unit is put into operation.
                                                                                                         The duration of service S in hours (to FEM 9.755) is calculated by means of the
                                                                                                         following formula:
                                                                                                         S = LK × LF                                              S = Duration of service in full load hours

                                                                                                                                                                  LK = FWL counter reading

                                                                                                                                                                  LF = Load spectrum factor

                      Example:                                                                           DR 3 3m
                                                                                                         Counter LK = 10014
                                                                                                         LF = 0,5425 x 106

                                                                                                         Full load hours S = 10014 x 0,0005425 = 5,43 hours




                      FGB-2/FWL as overload protection and load spectrum recorder for hoist units with pole-changing motors
                      Switch 8 ON = overload protection

                                   L1, L2, L3, PE



                                                                        F1




                                                                                                                                                                  Equipment designation
                                                                                                                                                                  B1    = Strain gauge
                                                                                                                                                                  F1    = Fuse ‘Hoist motor’
                                                           K1                                       K2          K3
                                                                                                                                                                  K1    = Contactor ‘Creep lifting/creep lowering’
                                                                                                                                                                  K2    = Contactor ‘Main lifting’
                                                                                                                                                                  K3    = Contactor ‘Main lowering’
                                                                                                                                                                  M1    = Creep – main hoist motor
                                                                          M                                                                                       P1    = Elapsed operating time counter
                                                                         3
                                                                                                                                                                  S1/S2 = Pushbutton lifting/lowering
                                                                             M1                                                                                   S3    = Emergency limit switch lifting/lowering
                                    L4                                                                                                                            S4    = Preliminary limit switch ‘Main lifting’
                                                                                                                                                   K2   K3
                                                 S2            S1                                                                                                 U1    = Frequency evaluator/load spectrum
                                                                                                                                                                          recorder, overload
                                                                                                                                                                  U2    = FGB-2 frequency generator
                                                                                                                A1                                      16        U3    = Hoist unit control (e.g. 250 ms re-start
                                            S1
                                          A1          1             2                           3
                                                                                                           U1                                   FWL          P1           block)
                                    U3                                                                          A2                1    2    3           10
                                          A2          4             5             6             7
                                                                                                                                  Screen
                                                                                                                                  Brown
                                                                                                                          Green

                                                                                                                                  White




                                                      13                          23
                                               U1                        U1
                                                      14                          24
                                                                                                                 U2                        FGB-2
                                            S3            S3            S3            S3
                                                                                                                      Screen




                                                                                                                      Yellow
                                                                                                                      Brown




                                                                        S4
                                                                                                                      Green

                                                                                                                      White




                                                 K2            K3            K3            K2
                                                                                                                     B1               ZMS
                                            K1                          K2            K3

                                    L5
                                                 Creep                            Main
                                          Lifting      Lowering                   Lifting           Lowering
                       Fig. 12                                                                                                                                                                          42356544.eps
20364044.p65/081105




                                                                                                                                                                                                                       27
     Cross travel limit switch




     Position switch XCK-MR

                 Position switch
                 2 x switching in steps with rotating stop




                                                                                                            Positive lock connector 6,3 mm with lock



                                                             Contact block    Contact block
                                                                        ‘A’              ‘B’
                                                                                                                                   Connector, 3-pole
                                                                                                                                                 Core 1 on pin 1
                                                                                                                                                 Core 2 on pin 2
                                                                                                                                                 Core 3 on pin 3
                                                                                                                                   Connector -X16
                                                Connection of cable on
                                                               switch:

                                                                                                                                   Connector, 3-pole
                                                                                                                                               Core 4 on pin 1
                                                                                                                                               Core 5 on pin 2
                                                                                                                                               Core 6 on pin 3
                                                                                                                                         5 mm offset without
                                                                    Screw-type union M20 with long
                                                                    thread (approx. 15 mm)                                               connector -X48
      Fig. 13
                                                                                                                                                                   42355444.eps




     Switching crossbar positions with                            Type XCK-MR54D1
     contact arrangement
                                                                       +180° +90° 0°           -90° -180°


                                                                                                        A11 A12
                                                                                                        B21 B22
                                                                                                        B11 B12


                                                                  With rotating stop


     Key data:
     Housing:                                                    Zinc die-cast
     Type of enclosure:                                          IP66
     Mechanical service life:                                    2 million switching cycles
     Actuating speed:                                            max. 90 m/min

     Min. moment for actuation:                                  0,5 Nm

     Positive opening:                                           0,75 Nm

     Cable unions:                                               3 x M20

     Rated operating data:                                       AC-15: 240 V; 3 A
                                                                 DC-13: 125 V; 0,55 A

     Connection/cross section:                                   Flat terminal with washer M3,5/max. 2 x 1,5 mm²
     Earth lead connection/cross section:                        Flat terminal with washer M3/max. 1,5 mm²

     Short-circuit protection:                                   Fusible link 10 A, gG (gL)
                                                                                                                                                                                  20364044.p65/081105




     Contact type:                                               No snap function, positive opening of NC contact 21-22



28
                      Option packages




                      Cross travel inverter

                      DR PRO and DR COM            Package                         1.1               1.2
                      Package 1                    Inverter                 DIC-4-004          DIC-4-007
                                                                            537 713 84         537 715 84
                                                   Braking resistor
                                                                                   -           537 732 84
                                                   120 Ohm 0,4 KW
                                                   Braking resistor
                                                                            537 730 84                 -
                                                   220 Ohm 0,2 KW

                                                   Order cable between trolley motor and FI separately, e.g. 4 x 1,5 + 2 x (2x0,5),
                                                   part no.: 719 096 45


                      Cross travel limit switch                                               Cross travel
                                                                                              limit switch
                      DR PRO and DR COM
                      Package 2                    EKDR 3 - 10     With mech. fittings        719 074 45
                                                   EZDR 5 - 10     With mech. fittings        719 174 45
                      Selection via logic
                      Fitted in the factory



                      Overload cut-out, F series   Package                   3.1               3.2            3.3                3.4      3.5                3.6
                      Only for DR PRO              Rope hoist              DR 3           DR 5, 10           DR 3          DR 5, 10      DR 3          DR 5, 10
                      Package 3                                            0,625 t            1,25 t         0,625 t        1,25 t      0,625 t         1,25 t
                                                   ZMS
                      Selection via logic                               491 390 44       491 391 44        491 390 44     491 391 44   491 390 44     491 391 44
                      Fitted in the factory        FGB-2 (terminals)                                                469 674 44
                                                                                469 669 44                          469 668 44                  469 667 44
                                                   FWL
                                                                                    42-48 V                         110-120 V                   220-240 V

                                                   Order cable LIYCY 3 X 0,5 mm² between FGB-2 and FWL separately,
                                                   part no. 464 495 44




                      Accessories for parameter    For programming the parameters, order an operating unit (key-pad, see table 1) or an
                      programming                  interface module and the ‘Parcom Compact’ parameter programming software (see
                                                   table 2).

                                                   Table 1
                                                   KP 500 operating unit                       537 722 84




                                                   Table 2
                                                   KP232 interface module                      537 769 84
                                                   RS 232 module       CM - 232                537 723 84
                                                   Data line PC 1,8 m                          537 237 84
                                                   Parcom Compact parameter
                                                                                               537 752 84
                                                   programming software
20364044.p65/081105




                                                                                                                                                                   29
30
                      Notes




20364044.p65/081105
20364044.p65/081105




                      Notes




31
                                                                                                                                                                      Printed in Germany Basse/081105/5H




Demag Cranes & Components GmbH
P.O. Box 67, D-58286 Wetter
Telephone (+49 2335) 92-0 · Telefax (+49 2335) 927676
www.demagcranes.com

Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, D-58286 Wetter   Subject to change. Not liable for errors or omissions.

				
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