720 IS 800
214 912 44
201204 EN
DR crane set
Standard cranes with EKDR
Technical data and instructions for assembly
21491244.p65/201204
2
Manufacturer:
Operating instructions
EKDR Com rope hoist
(Technical data and spare parts) 214 916 44 720 IS 813
DRS 112 – 200 wheel block system 214 276 44 720 IS 845.5
DFW-L-L travel units 214 331 44 720 IS 845.1
DFW-L-E travel units 214 362 44 720 IS 845.1
Demag EKDR Pro rope hoist 214 725 44 720 IS 813
DRC-10 radio remote control systems 214 920 44 720 IS 975
DRC-J radio remote control systems 214 975 44 720 IS 975
DSE-8R, 16 R control pendants 214 940 44 720 IS 975
Technical data
EKDR Pro rope hoist 203 520 44 714 IS 813
Demag DRS travel unit components 203 352 44 714 IS 845
KBK 0, KBK 25, KBK 100 power supply
via trailing cables 202 617 44 714 IS 963
KP-A / T clamp-type buffer 203 313 44 714 IS 888
Assembly instructions
KP-A / T clamp-type buffer 214 354 44 720 IS 888
Accompanying documents
Demag Cranes & Components GmbH
P.O. Box 67, D-58286 Wetter
Telephone (+2335) 92-0 · Telefax (+2335) 927676
www.demagcranes.com
3
21491244.p65/201204
Page
0 Foreword 4
0.1 Copyright 4
0.2 Customer service 4
0.3 Liability for defects 5
0.4 Limitations of liability 5
0.5 Definitions 6
1 Safety instructions 7
1.1 Symbols 7
1.2 Intended use 7
1.3 Inappropriate use 8
1.4 Basic information on safety 8
1.5 Selection and qualification of operating personnel 9
1.6 Safety instructions for assembly and disassembly 10
1.7 Safety instructions when first putting the unit into service
after completing assembly 10
1.8 Safety instructions for operation 10
1.9 Safety instructions for maintenance 11
2 Scope of delivery 13
3 Overview of DR rope hoist assembly 14
3.1 Adjusting the EKDR Pro/Com 3 - 5 – 10 low-headroom monorail hoist,
4/1, 2/1 and 4/2 rope reeving 14
3.1.1 Assembling trolleys of the DR 3, 5 and 10 range 14
4 Manufacturing tolerances of crane runways 16
5 Technical Description DFW travel unit 17
5.1 DFW-L-E overview 17
5.2 DFW-L-L overview 19
6 Crane set 21
6.1 Crane set with DFW travel unit 21
6.1.1 Design of the travel unit 21
6.1.2 Changing the span 22
6.2 KP-T16 clamp-type buffer 23
7 Electrical components 24
7.1 Illustration of the scope of supply of the flange clamps 26
7.2 Connector overview 27
7.3 Plug-and-socket connection for motors of the KB and Z series 28
7.3.1 Safety instructions 28
7.3.2 General 28
7.4 Electrical design and connector insert 29
7.4.1 ZBF two-speed motor with brake 29
7.4.2 GF combined brake module 29
8 Crane anti-collision device 30
9 Geared limit switch for the DR rope hoist 33
9.1 Geared limit switch 33
9.1.1 Determining the cut-out points for the geared limit switch 33
9.2 Instructions for adjusting the geared limit switch 35
These instructions are no operating instructions for the end user, but assembly instructions for the company being responsible for assembly and erection
of the rail-guided handling equipment.
Special operating instructions for the overall installation must be prepared by
the corresponding crane manufacturer.
Table of contents
21491244.p65/201204
4
0 Foreword
You have purchased a Demag product.
This rail-guided handling equipment was manufactured in accordance with German
and European standards and regulations, e.g. EC Machinery Directive 98/37/EC,
and state-of-the-art engineering principles.
These assembly instructions are designed to provide the crane manufacturer with
appropriate instructions for safe and correct assembly and installation. The operating and assembly instructions of the corresponding products stated in the individual
sub-chapters form parts of these assembly instructions.
Every individual given the task of transporting, installing, commissioning, operating,
maintaining and repairing our rail-guided handling equipment and additional equipment must have read and understood
• the assembly instructions
• the operating instructions,
• the safety regulations and
• the safety instructions in the individual chapters and sections.
The assembly instructions must be available to the assembly personnel at all times
in order to prevent assembly errors and to ensure smooth and trouble-free operation of our products.
These assembly instructions must be treated confidentially. They should only be
used by authorized personnel. They may only be entrusted or made available to
third parties with the prior written consent of Demag.
All documents are protected within the sense of copyright law.
No part of this documentation may be reproduced, utilized or transmitted without
specific prior consent. Infringements are an offence resulting in obligatory compensatory damages.
All industrial rights reserved.
For technical information on Demag products and their systematic application,
please refer to one of our after-sales service stations, the relevant representative
or to our main office in Wetter.
Our after-sales service will provide you with all technical information on Demag
products and their systematic application.
Should you have any questions regarding our products, please refer to one of our
after-sales service stations, the relevant representative or the manufacturer.
Kindly quote the serial or order number (see test and inspection booklet, load
capacity plate on the crane) in any correspondence or for spare part orders.
Specifying this data ensures that you receive the correct information or the required
spare parts.
The relevant after-sales service station of Demag is specified for example on the
back page of the hoist unit test and inspection booklet.
0.2 Customer service
0.1 Copyright
5
21491244.p65/201204
These operating instructions must be read carefully before installing and putting the
rope hoist into operation.
We assume no liability for any damage and malfunctions resulting from failure to
comply with the operating instructions.
Any liability claims for defects must be made by quoting the order number immediately on detecting the defect.
Any liability claims for defects are void in the event of:
• inappropriate use,
• faulty devices or equipment connected or attached to the system which are not
part of our scope of supplies and services,
• use of non-genuine spare parts and accessories,
• refurbishment or modification of the product unless approved in writing by
Demag.
Wearing parts are not subject to liability for defects.
All technical information, data and instructions for operation contained in these
operating instructions were up-to-date on going to print and are compiled on the
basis of our experience and to the best of our knowledge.
We reserve the right to incorporate technical modifications within the scope of further development of the rope hoists which are the subject of these operating instructions.
The information, illustrations and descriptions contained in these operating instructions are therefore only intended for information purposes.
The descriptions and illustrations contained in this documentation do not necessarily correspond to the scope of delivery or any subsequent spare part delivery, either;
the drawings and illustrations are not to scale.
Only documentation belonging to the actual order is valid.
We assume no liability for damage and malfunctions caused as a result of operating
errors, non-compliance with these operating instructions or inappropriate repairs
and maintenance.
We expressly point out that only genuine Demag spare parts and accessories approved by us may be used. Accordingly, this also applies to other manufacturers’
parts supplied by us.
For safety reasons, the fitting and use of spare parts or accessories which have not
been approved and unauthorized modification and conversion of the product are
not permitted and exempt Demag from any liability for damages resulting therefrom.
With the exclusion of any further claims, we are liable for any defects or omissions
on our part in the products or documentation supplied within the scope of the liability obligations entered into in the original contract. Any further claims, in particular
any and all claims for damages, are excluded with the exception of legal claims in
accordance with product liability legislation.
0.3 Liability for defects
0.4 Limitations of liability
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6
0.5 Definitions
Owner
Owners (employer, company) are defined as persons who own the rail-guided
handling equipment and who use it appropriately.
Operating personnel/operator
Operating personnel or operators are defined as persons entrusted by the owner
of the rail-guided handling equipment with operation of the equipment.
Specialist personnel
Specialist personnel are defined as persons assigned by the owner of the railguided handling equipment to carry out special tasks such as installation, settingup, maintenance and fault elimination.
Qualified electrician
Qualified electricians are defined as persons who, owing to their technical training,
knowledge and experience of electrical installations as well as knowledge of the
relevant standards, codes of practice and regulations, are able to assess the tasks
given to them and to identify and eliminate potential hazards.
Trained person
Trained persons are defined as persons who have been instructed and trained for
the tasks assigned to them and on the possible hazards resulting from incorrect
handling and who have been informed about the required protective devices,
protective measures, relevant regulations, codes of practice, accident prevention
regulations and operating conditions and who have proven their qualifications.
Experienced technician
Experienced technicians are defined as persons, who, owing to their technical
training and experience, have sufficient knowledge of rail-guided handling equipment and are familiar with the relevant national industrial safety regulations, codes
of practice, accident prevention regulations, directives and generally accepted
engineering standards enabling them to judge the safe operating condition of railguided handling equipment.
Assigned expert engineer (in the Federal Republic of Germany according to
BGV D8, § 23, for determining the S.W.P.)
An assigned expert engineer is defined as an experienced technician specifically
assigned by the manufacturer to determine the remaining duration of service
(service life) of rail-guide handling equipment (S.W.P. = safe working period) and
to carry out a general overhaul of rail-guided handling equipment.
Authorized expert engineer (in the Federal Republic of Germany according to
BGV D6, § 28)
In addition to the expert engineers of the Technical Supervisory and Inspection
Board, an authorized expert engineer for the inspection of rail-guided handling
equipment is defined as an expert engineer authorized by the Industrial Employers’
Mutual Insurance Association.
Rail-guided handling equipment
Rail-guided handling equipment are systems used for lifting and moving loads, such
as cranes, crabs and travelling hoist units, rail systems.
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21491244.p65/201204
1 Safety instructions
1.1 Symbols
The following symbols and recommendations indicate potential safety hazards or
causes of damage or provide useful information.
Hazard warning
This symbol appears in the assembly instructions next to all instructions relating to
safety at work wherever a potential hazard to life and limb exists if the instructions
are not complied with.
Follow these instructions at all times and be particularly vigilant and cautious.
Pass on safety instructions to all persons entrusted with working on the equipment
including the track and power supply.
In addition, observe all general safety regulations at all times.
Warning against dangerous electrical voltage
Contact with live parts can result in immediate death. Protective covers (e.g. covers
and enclosures) of electrical assemblies or those marked with this sign may only be
opened by qualified electricians. Before opening, all relevant operating, control, feed
or other voltages must be disconnected.
Warning against suspended load
Any person remaining in this danger zone may suffer serious injury or death.
Operating hazard for the installation
This symbol in the assembly instructions indicates all warnings which, if not complied with, may result in damage to the rail-guided equipment or the load.
Rail-guided handling equipment is only intended for lifting and moving loads and
may be used as stationary or travelling units.
Rail-guided handling equipment may only be operated when in perfect working
order by trained personnel in accordance with the relevant safety and accident
prevention regulations. This also includes compliance with the operating and maintenance conditions specified in the assembly and operating instructions.
Rail-guided handling equipment is industrial equipment operated with a rated voltage of up to 1000 V from high-voltage supply systems.
Power feed is via power supply lines (mobile cables, open or enclosed power conductor systems, cable drums). These systems lead up to the terminals of the main
switch (mains connection switch, isolating switch).
The relevant isolating switches must be switched off and secured when performing
maintenance/repair work. During operation or when the main switch is not switched
off, electrical components inside enclosures, motors, switchgear cabinets, terminal
boxes, etc., carry dangerous voltages.
Serious personal injury or damage to property may occur in the event of:
• unauthorized removal of covers,
• inappropriate use of rail-guided handling equipment
• incorrect operation
• insufficient maintenance,
• exceeding the maximum permitted load (The rated load capacity/S.W.L. is the
maximum permitted load. Pay attention to the sum of the load to be lifted and
the load handling attachment.)
• Working on live parts.
1.2 Intended use
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8
1.3 Inappropriate use
Certain work and practices are prohibited when using rail-guided handling equipment as they may involve danger to life and limb and result in lasting damage to
rail-guided handling equipment, e.g.:
• Unsafe load handling (e.g. swinging the load)
• Handling suspended loads above persons
• Pulling or dragging suspended loads at an angle
• Pulling free fixed or obstructed loads
• Exceeding the maximum permitted load and permitted load dimensions
• Leaving suspended loads unsupervised
• Running load-supporting means (chains and ropes) over edges.
• Using load-supporting means (chains and ropes) as a load bearing sling.
• Subjecting the control pendant to inappropriate mechanical loads
• Allowing loads to drop when the load-supporting means are in a slack condition
• Failing to pick up loads from a solid base, but, for example, from a load handling
attachment
• Transporting persons, unless lifting devices are specifically approved for transporting persons
• Manipulating electrical equipment
Persons under the influence of drugs, alcohol or medicines which affect reactions
must not install, operate, put into service, maintain, repair or disassemble rail-guided handling equipment.
Any conversions and modifications to the installation must comply with the technical
safety requirements. Work on electrical equipment of rail-guided handling equipment may only be carried out by qualified electricians in accordance with electrical
regulations. In the event of malfunctions, rail-guided handling equipment must be
stopped, switched off and the relevant main switches locked immediately. Defects
must be rectified immediately.
National accident prevention regulations and codes of practice and general safety
regulations must be observed when operating our products. Important information
and instructions are marked by corresponding symbols. Follow these operating and
safety instructions to avoid personal injury and damage to machinery.
The operating instructions must be kept available at the place where rail-guided
handling equipment is in use at all times.
They include significant aspects and appropriate excerpts from the relevant guidelines, standards and regulations.
The owner must instruct his personnel appropriately.
If the safety instructions given in these operating instructions are not observed in
any way, personal injury or even death can result.
Observe general statutory and other obligatory regulations relating to accident prevention and environmental protection and basic health and safety requirements in
addition to those included in these operating instructions.
Such requirements may relate, for example, to the handling of hazardous materials
or the provision/wearing of personal protection equipment.
Comply with these regulations and general accident prevention regulations relevant
for the place at which rail-guided handling equipment is used and follow the instructions therein when working with the equipment.
Rail-guided handling equipment may still constitute a danger to life and limb if it is
not installed, operated, maintained or used appropriately by personnel which have
not been trained or specially instructed.
The operating instructions must, if required, be supplemented by the owner with
instructions and information (e.g. factory regulations) relating to organization of
work, working procedures, operating personnel, etc. Supervising and reporting
obligations as well as special operating conditions must also be taken into
consideration.
1.4 General safety
information
9
21491244.p65/201204
Personnel assigned to working with rail-guided handling equipment must have read
and understood the operating instructions and, in particular, the section on safety
information.
All activities relating to rail-guided handling equipment which are not described in
these operating instructions may only be carried out by specialist personnel
specifically trained for rail-guided handling equipment.
The owner must ensure that personnel work in a safety and hazard-conscious
manner in compliance with the operating instructions.
The owner must ensure that rail-guided handling equipment is only operated when
in proper working order and that all relevant safety requirements and regulations are
complied with.
Rail-guided handling equipment must be taken out of service immediately if functional defects or irregularities are detected.
In the event of a stoppage (e.g. if defects regarding safe and reliable operation are
detected, in emergency situations, in the event of operating malfunctions, for repairs
and maintenance purposes, if damage is detected or after finishing work) the operator/experienced technician must carry out all prescribed safety measures (e.g. for
cranes operating outdoors, ensure wind drift safety catch is fitted) or observe that
they are automatically carried out.
Personal protective clothing must be worn
as necessary or as required by regulations.
Personnel must not wear loose clothing, jewellery including rings or long hair loose.
Injury may occur, for example, by being caught or drawn into the mechanism.
All safety and hazard warnings on rail-guided handling equipment, their access
routes and their mains connection switches must be preserved completely and in
legible condition.
Inching (i.e. giving short pulses to the motor) must always be avoided.
Emergency limit stop devices (e.g. slipping clutch or emergency limit switch) must
not be approached in normal operation.
Modifications, additions to and conversions of rail-guided handling equipment
which may impair safety in any way must not be carried out without the approval
of Demag. This also applies to the fitting and adjusting of safety devices as well as
for performing welds on load bearing parts.
Safety devices must not be rendered inoperative.
Only genuine Demag spare parts may be used.
Observe prescribed deadlines or those specified in the operating instructions for
routine checks/inspections.
For independent operation or maintenance of rail-guided handling equipment, the
owner may only employ persons
• who are at least 18 years of age,
• who are mentally and physically suitable,
• who have been instructed in the operation and maintenance of rail-guided handling equipmentand have proven their qualification to the owner in this respect
(in addition to theoretical training, instruction also includes sufficient practical
operating experience as well as acquiring the ability to identify defects which are
a hazard to safe operation),
• who can be expected to carry out the work assigned to them reliably.
The owner must assign operating and maintenance personnel to their relevant
tasks.
1.5 Selection and qualification of operating
personnel
21491244.p65/201204
10
• Installation and disassembly work may only be performed by experienced technicians.
• Installation and disassembly work must be co-ordinated by the person carrying
out the work and the owner within the scope of their responsibility.
• The danger zone must be made safe.
• The installation must be isolated in accordance with the relevant electrical regulations.
• Customer-specific regulations must be observed.
• Only appropriate, tested and calibrated tools and equipment may be used.
• The electrode holder and earth must be connected to the same assembly when
welding work is carried out. If the current flow is returned via protective conductors, screening elements or anti-friction bearings, serious damage may be
caused to these or other components.
• The working area must be made safe.
• First check that the voltage and frequency specified on the data plates match the
owner’s mains power supply
• All clearance dimensions and safety distances (see approval drawing) must be
checked before putting the unit into service.
• In the course of putting the product into service, it may be necessary to render
safety devices or features inoperative when carrying out adjustments or function
checks.
• When putting the unit into service, it may be necessary to perform work in the
danger zone, therefore, it must be ensured that only appropriately trained personnel are employed for this work.
The operator must check the function of the brakes and emergency limit stop devices before starting work.
All instructions and measures described in the assembly and operating instructions
with regard to safe operation and items concerning general safety and accident
prevention which have to be observed before, during and after putting into service
must be strictly complied with. Any failure to comply can lead to accidents resulting
in fatalities.
Rail-guided handling equipment must be taken out of service immediately or not put
into operation if any defects relating to operating safety and reliability are detected.
Safety devices must not be rendered inoperative or modified in contradiction to their
intended use.
Only operate rail-guided handling equipment when all protective devices and safetyrelevant equipment, e.g. movable protective devices and emergency-stop devices,
are fitted and fully functioning.
Anybody who identifies an immediate danger of personal injury must actuate the
emergency stop button without delay. This also applies in the case of damage occurring to parts of the installation and equipment which makes immediate stoppage
necessary. After an ”emergency-stop”, the operator must not switch on and restart
rail-guided handling equipment until an experienced technician is satisfied that the
cause which led to actuation of this function has been rectified and that continued
operation of the installation constitutes no further hazard.
1.6 Safety instructions for
assembly and disassembly
1.7 Safety instructions
when first putting the
unit into service after
completing assembly
1.8 Safety instructions for
operation
11
21491244.p65/201204
Rail-guided handling equipment must be switched off immediately in the event of
the following faults:
• Damage to electrical devices and cables as well as parts of the insulation.
• Brake and safety device failure.
Ensure that nobody is endangered by operation of rail-guided handling equipment
before switching it on or putting it into operation.
If the operator notices persons who may be exposed to a risk to health or personal
safety by operation of the equipment, he must suspend operation immediately and
may not resume operation again until the persons are outside the danger zone.
Before putting rail-guided handling equipment into operation, the operator must be
satisfied that it is in safe and correct operating condition.
Work on rail-guided handling equipment may only be carried out when instructions
to this effect have been issued, when operation and function of the equipment have
been explained and when the working and danger zone has been made safe.
Cooling devices and ventilation openings, may not be rendered permanently inoperative (e.g. covered or closed).
Special local conditions or special applications can lead to situations which were
not known when this chapter was written. In such cases, special safety measures
must be implemented by the owner.
Maintenance measures are defined as regular maintenance, inspection and repair
work.
Mechanical and electrical repairs and maintenance work may only be carried out by
appropriately trained personnel (experienced technicians). Demag specialists are
also trained to work on specific products.
Adjustment, maintenance and inspection activities and inspection deadlines including specifications concerning replacement of parts/assemblies prescribed in the
assembly and operating instructions must be observed.
Ensure that all electrical components are de-energized before commencing work on
electrical installations and devices. When all work on rail-guided handling equipment
has been completed, operation of the equipment must not resume until the owner
has given approval to this effect.
Unauthorized persons must be prohibited from carrying out work on machinery or
parts of rail-guided handling equipment. Before starting all repair and maintenance
work, the product must be switched off, taken out of operation and secured
(switches must be locked) against accidental or unauthorized putting into operation
(restarting).
It must be ensured that
• rail-guided handling equipment is switched off and checked that it is de-energized and, in special cases, isolated,
• moving parts are stationary and stopped,
• moving parts cannot start moving while maintenance work is being carried out,
• the power supply cannot be accidentally restored as long as the rail-guided
handling equipment has been taken out of service for maintenance and repair
purposes, Ensure that operating and auxiliary materials as well as replaced parts
are disposed of in a safe and environmentally sound way.
1.9 Safety instructions for
maintenance
21491244.p65/201204
12
Instructions for repair work in the course of operation
The danger zone must be marked off with red/white safety chains or safety tape
and indicated with warning signs.
In each individual case, the owner or the person specified by him must check
whether the relevant work may be carried out in the course of operation without risk
of personal injury owing to the particular local conditions.
Use only calibrated and appropriate tools and auxiliary materials for maintenance,
inspection and repair work, in order to avoid injury.
If there is a risk of objects falling, the danger zone must be made safe.
Maintain a sufficient safety distance to rotating parts to prevent clothing, parts of
the body or hair becoming entangled.
Avoid naked flames, extreme heat and sparks in the vicinity of cleaning agents and
flammable parts or parts liable to deformation (e.g. wood, plastic parts, oil, grease)
in electrical installations – non-compliance may result in fire hazard. Harmful gases
may evolve or insulation may be damaged.
Additional instructions for repair work on electrical equipment
Only genuine fuse links with specified amperage and tripping characteristics may be
used.
Defective fuse links must not be repaired or bridged and must only be replaced by
fuse links of the same type.
Switch off rail-guided handling equipment immediately in the event of electrical
power supply malfunctions.
Work on the electronic and electrical components or equipment may only be carried out by qualified electricians.
If inspection, maintenance and repair work is to be carried out on parts, these must
– if prescribed by regulations – be isolated. First verify the safe isolation of the parts
from the supply before commencing work.
The electrical equipment of rail-guided handling equipment must be inspected and
checked at regular intervals. Defects, such as loose connections, damaged cables
and worn contactor contacts must be rectified immediately.
Electrical equipment must be replaced as a preventive measure on reaching the
limit of its service life.
If work has to be carried out on live parts, a second person must be available to
actuate the emergency-stop button or mains connection switch/isolating switch in
order to disconnect the power supply in an emergency. The second person must
be familiar with resuscitation measures.
Only use insulated tools.
Before disconnecting and connecting electrical plug-and-socket connections,
always disconnect them from the supply (this does not apply to mains connections,
provided they do not represent a dangerous contact voltage in the sense of the
safety regulations).
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21491244.p65/201204
42678444.eps
2 Scope of delivery
1 Monorail hoist with travel drive
2 Crane girder 1)
3 Travel unit with drive
4 Control pendant/Radio remote control
5 Power supply
6 Crane runway 1)
7 Electrical equipment of the crane
8 Electrical equipment of the monorail hoist
– with lifting limit switch
– with load detector
EKKE single-girder crane
9 Clamp-type buffer
10 C-rail subassembly
11 Power supply of the
monorail hoist
3
2
8
1
4
5
7
6
10
9
4
11
1) Not included in the scope of supply
21491244.p65/201204
14
Overview of the necessary assembly work.
The following illustarations show the general work steps.
For correct assembly observe the specifications in the corresponding
Operating instructions: EKDR Pro 3 - 5 - 10 214 725 44
Operating instructions: EKDR Com 3 - 5 – 10 214 916 44
1
4
6
3
2
5
7
5
4/1 reeving
3.1.1 Assembling trolleys of the 3,
5 and 10 range
3 Overview of DR rope hoist assembly
3.1 Adjusting EKDR Pro/-Com 3 – 5 – 10 low-headroom monorail hoists,
4/1, 2/1 and 4/2 rope reeving
2/1 reeving
42576445.eps
4/2 reeving
EKDR Pro 10
42063545.eps
42583644.eps
42584244.eps
Safely support the travel unit, before you place it onto the
girder in order to avoid any danger due to
• crushing hazard
• shearing hazard.
This support may only be removed after supporting roller
(6) has been adjusted.
Slide wheel legs (1) – travel motor side – on connecting rods
(2 + 3)(loosen threaded pin (5) before).
15
21491244.p65/201204
x1
x2
b + 1mm
2
6
3
1
2
4
5
6
7
5
b1
b2
6
7
4
9
1
8
b1
2
42583844.eps
Place the travel rollers of wheel legs (4) – drum side – onto the girder flange and slide wheel legs (1) on the opposite
side – travel motor side – towards the girder.
Reference dimension between both opposite guide rollers is flange width b +1 mm.
After adjusting the travel unit, press supporting roller (6) against the bottom flange of the girder by means of tensioning
screw (7). Tension supporting roller (6) until the travel wheel is in contact with the girder flange.
Assembly of the travel unit on the track girder
Assembly of the spacer sleeves
(only on the crossbar side with supporting roller)
1. Measure distance x1 between wheel legs (4) and supporting roller (6).
2. Measure distance x2 between wheel legs (1) and retaining ring with washer (8).
3. This is done to determine the number of spacer sleeves (9).
Spacer sleeve (9) is now opened and fitted on connecting rods (2).
Spacer sleeve dimensions (9)
egnaR
mmnihtdiW
1b2b2b+1b
5RD/3RD9,222,511,83
01RD3,228,411,73
Determine dimension L of pre-tensioned pressure spring (10).
To obtain the pressure force of supporting rollers (6), shorten
length L of pressure spring (10) by “dimension x”.
egnaR3RD5RD01RD
]mm[x-.miD2,6-2,5-5,7-
42583744.eps
Final adjustment of the supporting rollers
L
6
6
7
10
Fit the clamps for fastening
the cable in one row.
Locking hook
Pre-tensioning of pressure spring (10)
After having adjusted the travel unit, press supporting roller (6) against the bottom flange of the girder
by means of tensioning screw (7). Tension supporting roller (6) until the travel wheel is in contact with
the girder flange.
42584044.eps
42583944.eps
Fix side cheek (1) on connecting rod (2+3)
with threaded pins (5).
DR 3 range = 150 Nm
DR 5/10 range = 200 Nm
Minimum flange thickness
DR 3 min. 10 mm
DR 5 min. 12 mm
DR 10 min. 15 mm
21491244.p65/201204
16
4 Manufacturing tolerances of crane runways
S min
S
S max
41409444.eps
-B-B +B
2000
2000
2000
b
b
b
41409544.eps
2000
-C +C
2000
2000
c
c
c
41409644.eps
s
E
+E
41409744.eps
Quelle: VDI 3576 Recommendation: Tolerance class 2
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ertnecliarehtotecnereferhtiwsliar
htgnelyawnurenarcdna
S
xam
SA+s=
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A–s=
:m61£srof
mm3±=A
:m61>srof
])61–s(52,0+3[±=A
mmniA
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:m61£srof
mm5±=A
:m61>srof
])61–s(52,0+5[±=A
mmniA
mnisesu
:m61£srof
mm8±=A
:m61>srof
])61–s(52,0+8[±=A
mmniA
mn
isesu
BecnareloT
liarehtfossenthgiartslaretalehtfo
enarcehtotecnereferhtiwdaeh
htgnelyawnur
becnareloT
htiw
ssenthgiartslaretalehtfo
derusaemmm0002otecnerefer
tniopynata)htgnelelpmas(htgnel
daehliarehtfo
nalpninee
sliarafonoitisoP
mm5±=B
mm1=b
mm01±=B
mm1=b
mm02±=B
mm2=b
CecnareloT
otecnereferhtiwssenthgiartsehtfo
ertnecliarenarcehtfothgieheht
htgnel
liarenarcdna
cecnareloT
otecnereferhtiwssenthgiartsehtfo
elpmas(htgnelderusaemmm0002
ehtfotniopynata)tnem
erusaem
yawnurenarc noitavelenineesliarafonoitisoP
)epolslanidutignol(
mm5±=C
mm1=c
mm01±=C
mm2=c
mm02±=C
mm4=c
EecnareloT
otecnereferhtiwthgiehehtfo
tastniopgnirusaemralucidneprep
yawnurenarcehtfotniopyreve
nirehtonaenootnoitalernisliarfonoitisoP
)epolsesrevsnart(noitavele
sx%/º5,0±=E
mmni
mmnise
su
E
xam
mm5±=
sx%/º1±=E
mmni
mmnisesu
E
xam
mm01±=
sx%/º2±=E
mmni
mmnisesu
E
xam
mm02±=
17
21491244.p65/201204
5 Technical Description DFW travel unit
Assembling the travel unit/supporting
structure
The counterbores in the travel units and the distance washers fixed in the connecting plate must be free of rust, dust, grease, paint and other contaminants.
Execution of the bolted connection:
• Remove covers of the access holes.
• The distance washers on the connecting plate in the recess of the bore hole are
always welded on the bottom (tack-welded).
• Connect the travel unit to the crane girder according to the above illustration
(bolt heads in the travel unit).
Only the parts included in the supply may be used for the connection.
1. Hex. bolt M20 x 85 x 46, DIN 6914, strength class 10.9 HV
2. Hex. nut M20 DIN 6915, strength class 10 HV
3. Hardened washer 21 x 37 x 8, DIN 6916, strength class C45 VHV
4. Distance washer 22 x 50 x 10, min. tensile strength 520 N/mm
2
• Tighten diagonal pairs of all screws using a torque wrench.
Tightening torque: 554 Nm
• Close access holes with covers.
• For outdoor operation the gap between the travel unit and the connecting plate
is sealed with silicone sealing compound on the top and on the sides.
Demag DFW travel units are driven rail-mounted travel units of compact design
and can be connected direct to load-bearing structures by means of an existing
mounting surface.
The travel unit girder, designed on the basis of the latest findings in the steelwork
sector, consists of a box girder profile resistant to torsion. Low tolerances for differences in the runway gauge, skewing and misalignment provide for excellent travel
characteristics, even at high loads.
The travel unit features a driven Demag DRS wheel block, to which a gearbox and
motor are fitted, as well as a non-driven DRS wheel block.
Specially matched motors of heavy-duty design ensure smooth starting of the travel
unit, whether with or without a load, with favourable speed/torque characteristics.
Only perfect crane alignment geometry ensures good operating characteristics of
the crane. Thus, in order to maintain the manufacturing accuracy once reached, the
assembly of travel units and crane girder must be carried out carefully.
5.1 DFW-L-E travel unit
overview
21436102.eps
Travel unit with a side crane girder connection (standard)
42672644.eps
Counterbores
Distance washers tack-welded in the recess (always on the bottom)
Connecting plate
Crane girderTravel unit
3
1
32
4
HT mark
Bevel on nut side
Bevel under bolt
head
21491244.p65/201204
18
Jacking up the travel unit
Certain assembly work requires that the travel unit is jacked up, in order to remove
the load from the travel wheels (wheel block).
For this purpose a winch or similar lifting device is fixed under the diaphragm plate
of the travel unit and the travel unit is lifted.
It is sufficient to lift the travel unit by a few millimeters.
The lifted travel unit must be secured by spacers between the travel unit and the
travel rail. In order to avoid damage, the spacers must be arranged in the position
shown above.
21436103.eps
203 for travel wheel 112
233 for travel wheel 125
288 for travel wheel 160
353 for travel wheel 200
Connecting side
Diaphragm
plate
19
21491244.p65/201204
5.2 DFW-L-L travel unit
overview
Demag travel units as driven rail-mounted travel units of compact design can be
connected direct to load-bearing structures.
The travel unit girder, designed on the basis of the latest findings, consists of a box
girder profile resistant to torsion with welded diaphragm plates. Low tolerances for
differences in the runway gauge, skewing and misalignment provide for excellent
travel characteristics, even at high loads.
Each of the two travel wheels of the travel unit is mounted in a wheel block. One
of the two wheel blocks can be driven by a Demag travel drive (offset gearbox +
motor).
Specially matched Demag squirrel-cage rotor brake motors ensure smooth starting
of the travel unit, whether with or without a load, with favourable speed/torque
characteristics.
Only perfect crane alignment geometry ensures good operating characteristics of
the crane. Thus, in order to maintain the manufacturing accuracy once reached, the
assembly of travel units and crane girder must be carried out carefully.
The contact surface on the travel unit and crane girder as well as the bore holes for
the bolted connection must be free of rust, dust, grease, paint and other contaminants.
For the bolted connection only high-tensile (HT) bolts M16 may be used and tightened with the corresponding tightening torque (see bolted connection).
For the welded connection the travel units and the crane girder must be aligned
paralel to each other. No air gap may be added, when the components are welded
together.
Assembling the travel unit/supporting
structure
21433002.eps
21433001.eps
3
Crane girder
HT nut
DIN 6915
HT bolt
DIN 6914
Crane girder
Bolted connection
For crane girder HE-A 180 to 280:
HT bolt: M16x50 DIN 6914 Part no.: 316 091 99
For crane girder HE-A 300 to 400:
HT bolt: M16x55 DIN 6914 Part no.: 316 095 99
For crane girder HE-A 450 to 550:
HT bolt: M16x65 DIN 6914 Part no.: 316 060 99
For crane girder HE-A 180 to 550:
HT nut: M16 DIN 6915 Part no.: 316 207 99
HT washer: 17x30x4 DIN 6916 Part no.: 316 211 99
Only the parts included in the supply may be used for the connection. Tighten
diagonal pairs of all screws using a torque wrench.
Tightening torque: 284 Nm
HT bolt
DIN 6916
21491244.p65/201204
20
Jacking up the travel unit
Certain assembly work requires that the travel unit is jacked up, in order to remove
the load from the travel wheels.
For this purpose a winch or similar lifting device is fixed in the travel wheel area of
the travel unit (for example: the winch is fixed approx. 300 mm from the end of the
travel uni and the travel unit is lifted.
It is sufficient to lift the travel unit by a few millimeters.
The lifted travel unit must be secured against leaving the rails by spacers between
the travel unit girder and the travel rail. Subsequently the winch or similar lifting
device is unloaded so that it can be removed.
In order to avoid damage, the spacers must be arranged in the position shown
above and removed after assembly.
21433003.eps
205
Spacer
21
21491244.p65/201204
3
2
8
1
4
5
7
6
10
9
4
11
6 Crane set
6.1.1 Design of the travel unit
The travel unit consists of a DRS wheel block on the non-driven side and a DRS
wheel block with modular drive system (torque bracket, gearbox and motor) on
the driven side. The connection of the gearbox to the torque bracket provides for
different mounting positions relative to the wheel block. The drive shaft transmits
the torque into the splined travel wheel hub via a splined journal shaft free of constraining forces and with low play.
42678844.eps
Illustration of the torque bracket 112-1 to MA 200-1 connection
6.1 Crane set with DFW travel unit
42678444.eps
1 Monorail hoist with travel drive
2 Crane girder 1)
3 Travel unit with drive
4 Control pendant/Radio remote control
5 Power supply
6 Crane runway 1)
7 Electrical equipment of the crane
8 Electrical equipment of the monorail hoist
– with lifting limit switch
– with load detector
EKKE
9 Clamp-type buffers
10 C-rail subassembly
11 Power supply of the
monorail hoist
Supporting washer, shims
Spacer elements
DRS wheel
block
Retaining ring
Buffer
Travel unit
Modular drive system:
- Motor
- Gearbox
- Torque bracket
Pin
Lock washer
(serrated lock
washer)
1) Not included in the scope of supply
21491244.p65/201204
22
21436106.eps
Spacer elements
Retaining ring
Pin
Supporting
washer (play
compensated
with shims)
6.1.2 Changing the span
The span can be changed by means of replaceable spacer elements. The standard
assignment and the max. adjusting range are listed in the table.
42679744.eps
WFD
mmninisnoisnemiD
4bb egnargnitsujda.xam
21107016±
521076 4±
06158516±
002595101±
b
b4
Spacer elements
Fill the distance
with spacer
elements.
23
21491244.p65/201204
6.2 KP-T16 clamp-type buffer
1
1
2
2
90˚
1
1
Slide the clamp-type buffer onto the runway girder. Slightly
tighten grub screws (1) on both sides.
Slightly tighten hexagon nuts (2) on both sides.
Align the clamp-type buffer.
41910844.eps
41910944.eps
41911044.eps
41911144.eps
41911244.eps
Fig. 3
Fig. 4
Grub screws (1)
Tightening torque = 20 Nm
alternately tighten to same amount.
Only the supplied grub screws may be used.
M 10 x 70 to DIN 916
Hex. nuts (2)
Tightening torque = 40 Nm
Buffer profile part nos.: KP-T16 826 953 44
Safety instructions
All bolted connections of the clamp-type buffer must be checked for tight fit once a
year. Retighten to tightening torques specified in fig. 4 as required.
Loosened screws might result in the travel unit falling down.
For testing, run the hoist unit
against the clamp-type buffer
21491244.p65/201204
24
6
11
1
5
4
2
10
7
9
12
3
400
500
2000
≤
2000
≤
2000
≤
250
250
13
5
8
7 Electrical components
Depending on the span of the crane bridge the following quantities of the subassemblies item 8 to item 11 are used:
The scope of delivery includes:
Fig. 5
42678344.eps
1 EKDR incl. equipment set
2 Crane bridge enclosure complete
3 Power supply of the monorail hoist -W2, -W6
4 Mobile control/power supply system -W11
9 C rail subassembly 40 x 40 x 3 x 1500 mm
10 C rail subassembly 40 x 25 x 3 x 1500 mm
11 C rail subassembly 40 x 25 x 3 x 2200 mm
12 Track section 5000 mm
Track coupling (no illustration)
13 Clamp-type buffer
5 DSE suspension complete -W12
or DRC radio remote control
6 Long-travel drive supply line -W4
7 Long-travel drive supply line -W5
8 C rail subassembly 40 x 40 x 3 x 2200 mm
EKKE single-girder crane
ylbmessabuS enarcrepstsiohliaronomforebmuN
12
8metIx144635297x144635297
9metIx144035297x144035297
01metIxn44925297xn
54
910037
11metIx144535297x1
n ~ span x 0,6 - 1,28
C rail subassembly for crane bridges with one monorail hoist
• Item 8 - C rail subassembly 2200 x 40 x 40 x 3 (part no. 792 536 44)
for fixing the crane bridge enclosure, item.2 , which is simultaneously used for
guiding the cable to the long-travel drive.
• Item 9 - C rail subassembly 1500 x 40 x 40 x 3 (part no. 792 530 44)
for fixing the crane bridge enclosure, item 2
• Item 10 - C rail subassembly 1500 x 40 x 25 x 3 (part no. 792 529 44)
• Item 11 - C rail subassembly 2200 x 40 x 25 x 3 (part no. 792 535 44),
which is simultaneously used for guiding the cable to the long-travel drive.
C rail subassembly for crane bridges with two monorail hoists
• Item 8 - C rail subassembly 2200 x 40 x 40 x 3 (part no. 792 536 44)
for fixing the crane bridge enclosure, item 2
• Item 9 - C rail subassembly 1500 x 40 x 40 x 3 (part no. 792 530 44)
for fixing the crane bridge enclosure, item 2
• Item 10 and item 11
-n + 1 x C rail subassembly 2200 x 40 x 25 x 3 (part no. 730 019 45)
25
21491244.p65/201204
• Please note that for each 5m section of the KBK 25 rail, item 12, three rail
brackets are required.
• The first KBK rail including the cable accumulating section is equipped with an
additional rail bracket.
The cables are supplied cut to length, wired to connectors and fitted on
cable trolleys. For easy introduction of the cable trolleys into the KBK rail,
the trolleys are fixed successively.
• The first rail bracket of each KBK rail must be fitted 0.30 m from the rail joint
(measured up to the centre of the rail bracket).
• The distance I
w
(distance from centre of rail bracket <-> centre of rail bracket) is
2m.
• The two C rails 2200 x 40 x 40 x 3, item 8, and 1500 x 40 x 40 x 3, item 9, are
used for fitting the crane bridge enclosure.
• C rail 2200 x 40 x 25 x 3, item 11, is fitted to the other end of the KBK rail
system.
• A track stop is fitted on each track end.
• The cable -W4, item 7, is the “short” supply line to the long travel motor and
always has a length of 5.50 m.
• The cable -W5, item 6, is the “long” supply line to the long travel motor and the
length is determined depending on the span.
• Cable -W5 is fixed on the KBK rail by means of cable clamps ,
part-no. 964 364 44. Cables -W4, item 7, and -W5, item 6 are fixed on the C
rails by means of cable ties.
• The number of cable clamps is resulting from 2 cable clamps per KBK 25 rail
metre.
• Depending on the span and type of hoist unit, the following flat cables and bush
enclosures are used for the power supply to the monorail hoist and for the mobile
floor control:
Flat cables
4 G 4: Dimensions 19x6 - 22-8 Part no. 894 965 44
4 G 6: Dimensions 26x8 - 29x10 Part no. 504 227 44
4 G 10: Dimensions 32x9 - 35x12 Part no. 504 228 44
4 G 16: Dimensions 37x11 - 40x14 Part no. 471 355 44
Bush enclosure sets identical for both sides
4 G 4: VC-K-T2-Z-FK-6x20,5 Part no. 719 709 45
4 G 6: VC-K-T2-Z-FK-6X24 Part no. 719 016 45
4 G 10: VC-K-T2-Z-FK-7,5X29,5 Part no. 719 711 45
4 G 16: VC-K-T2-Z-FK-9X35 Part no. 719 712 45
• A control cable trolley is used for the mobile floor control, an additional towing
trolley is used for the supply cable of the monorail hoist. The number of cable
trolleys is stated together for the power supply to the monorail hoist and for the
mobile floor control (“sum of all cable trolleys”).
• The length of the control cable between the DSE-8R control pendant and plug
- X12 can be adapted to the customer’s requirements. (2 standard lengths of
6 m and 9 m)
The number of components depends on the span and is determined for each order.
In the following the components mentioned in the text are listed with their part
numbers:
The following rules apply:
noitangiseD
pmalcelbaCgnilpuockcarTliar52KBK-m5eitelbaC
.ontraP
44463469440251894451518944910189
noitangiseD
yellortelbaCyellortgniwoTyellortelbaclortnoC
elbacdne-liaR
pmalc
.ontraP
44030189440241894451418944
151189
21491244.p65/201204
26
C-rail with pre-assembled flange clamps
C-rail
Flange clamps
Rail brackets
End plugs
End plugs
7.1 Illustration of the
scope of supply of the
flange clamps
27
21491244.p65/201204
=19N11
-XF012
-W2
-W11
-W4
=19N11
-XM012
=19N11
- S012
=10D41
- M012
-W5
=10D41
- M016
X16 X48
=10D11
- XM024
=10D11
- XM012
=10D11
- XM021
=10D11
- XM025
=10D11
- XM013
-W2
-W6
-W202
-W206
-W16 -W17
=10D41
- S031
=10D41
- S034
-W1
=11D31
- XM011
=11D31
- XM012
=12D31
- XM011
-W206
-W202
=12D31
- XM012
-XF0..
-XF0..
-XF024
-XF012
-XF021
-XF025
-XF013
All cable connections equipped with connectors
42678544.eps
7.2 Connector overview
The connectors are marked with self-adhesive textile tape in different colours and
designed according to the following table:
elbaCnoitpircseD .ontraP
1W-ylppusrewoP tuohtiw
6W-&2W-
)²mm4(tsiohliaronomts1NAC&rewopelbacgniliarT 54000037
)²mm6(tsiohliaronomts1NAC&rewopelbacgniliarT 54100037
)²mm01(tsiohliaronomts1NAC&rewopelbacgniliarT 5420
0037
)²mm61(tsiohliaronomts1NAC&rewopelbacgniliarT 54300037
602W-&202W-
)²mm4(tsiohliaronomdn2NAC&rewopel
bacgniliarT 54510037
)²mm6(tsiohliaronomdn2NAC&rewopelbacgniliarT 54610037
)²mm01(tsiohliaronomdn2NAC&rew
opelbacgniliarT 54710037
)²mm61(tsiohliaronomdn2NAC&rewopelbacgniliarT 54810037
4W-
)tcatnoclatemibtuohtiw
rotomgnignahc-elop(trohselbacrotomlevartenarC 54500037
)tcatnoclatemibhtiwrotomgnignahc-elop(trohselbac
rotomlevartenarC 54600037
)tcatnoclatemibtuohtiwrotomretrevni-ycneuqerf(trohselbacrotomlevartenarC 54120
037
5W-
)tcatnoclatemibtuohtiwrotomgnignahc-elop(gnolelbacrotomlevartenarC 54500037
)tcatnoclatemibhtiwro
tomgnignahc-elop(gnolelbacrotomlevartenarC 54600037
)tcatnoclatemibhtiwrotomretrevni-ycneuqerf(gnolelba
crotomlevartenarC 54120037
11W-yellortelbaclortnocenilylppuS 54400037
m5.lpc21W-
R8-ESD 44573377
R61-ESD 44583
377
m9.lpc21W-
R8-ESD 44973377
R61-ESD 44983377
)1mX.lpc21W-
R8-ESD 44773377
R61-ESD 44783377
61W-hctiwstimillani
fgnillevartgnoL 54800037
71W- hctiwstimilyranimilerpgnillevartgnoL 54700037
!deriuqerhtgnelynanideredroebn
acseludomelbacesehT
.gniredronehwnapsetatS
1) Lengths depending on the order
Monorail
hoist 1
Monorail
hoist 2
Monorail hoist DR 3 -
DR 10
Monorail hoist DR 3 -
DR 10
Final limit switch
Crane limit switch X16
Preliminary limit switch
Crane limit switch X48
Crane bridge enclosure
KRBG
-A021 DR board
Cables plugged in/on the
KRBG form part of the crane
set
For frequency inverters:
No plug on the travel motor!
=10D41
Pole-changing
-XM011
FI motor
-XM024
=10D41
Pole-changing
-XM015
FI motor
-XM026
Optional limit switch!
21491244.p65/201204
28
• Disconnect the power supply before connecting the motor to or disconnecting it
from the power supply.
• If the line-side connection is not connected to a motor, the power supply must
be disconnected. Otherwise, the contacts carry voltage and fatal injuries may
occur.
• Keep the male and female connectors dry and clean. This applies in particular
after disconnecting the connection.
• Any damaged connectors must be replaced without delay.
• Do not allow connector cables to fall into materials, chips, waste, etc. Danger of
damage to the connector cable!
Demag has developed a plug-and-socket connection for KB. sliding rotor motors
and Z.. cylindrical rotor motors by means of which the corresponding motors can
be connected and disconnected within a very short time. Work-intensive individual
wiring in the terminal box is no longer necessary, a purely mechanical activity is
required only. The design eliminates connection errors and thus ensures safety of
the process.
These advantages are particularly significant for work to be carried out in an ergonomically unfavourable position and at large heights.
Since maintenance work is also involved in addition to installation and repair work, a
large amount of hours worked and costs incurred must be assumed, in particular in
larger installations. Long-term malfunctions, for example, which might result in interrupting the production process can therefore be avoided with this fast method. In
addition, the installation time and thus the overall costs of an installation are reduced. Inserts with a different number of poles can be used inside the new connector housing. This concept can also be integrated on an international level, since
Demag always incorporates standardized, commercially available plug inserts of the
Harting type.
The system is available as an option for the motor ranges of sizes 63 to 132. Although the extra engineering is reflected in a higher price, the customer is provided
with a more economical solution that is the result of later savings for maintenance
and repairs. Various industry sectors, such as the automotive industry, have recognized this benefit and already request this connector.
In the following, mounting of the plug-and-socket connection to Demag ZBF travel
motors is described.
All existing operating instructions continue to be valid also for motors with plug-andsocket connection.
7.3.2 General
7.3 Plug-and-socket connection for motors of
the KB and Z series
7.3.1 Safety instructions
• All connectors are assembledaccording to the connector identification when the
crane set is assembled.
• Connection to the power supply is made to the terminals of the isolator switch in
the crane bridge enclosure.
1. – Q011.1 L1
2. – Q011.3 L2
3. – Q011.5 L3
4. – X 1.PE PE
29
21491244.p65/201204
7.4 Electrical design and
connector insert
7.4.1 ZBF two-speed motor with
brake
The motor has two separate windings and can be operated with two speeds.
The GF combined brake module is used.
Circuit diagram 038 682 84 shows the connection of a Z-type motor with two
speeds and brake. The DC brake is connected to the power supply of the motor via
the GF module.
Additionally the GF module measures the motor current and switches the brake on
the DC side.
Power is supplied to the motor and to the brake with the phases 1L1, 1L2 and 1L3
via connections 1, 7 and 8 for high speed and via connections 1, 2 and 3 on the
connector for low speed.
038 682 84
Motor side
Line side
The module combines three functions in one unit. The module is used parallel to the
motor winding. It is used for normal excitation of the DC brake. Additionally motorcurrent dependent brake switch-off in the DC circuit is integrated in the GF module.
The GF module also features an integral varistor set that protects the high-pole
winding.
The GF combined module is used for pole-changing travel motors, sizes 63 - 100.
7.4.2 GF combined brake module
Connectors
Motor
High speed
Low
speed
2 windings, 2 speeds, 1 voltage Y/Y
Common power supply of motor and GF brake control module
21491244.p65/201204
30
The crane set can be ordered with an anti-collision device for a crane located in the
centre or on the side.
For this purpose, the type of switch-off (fast, general, 2-stage or without), the
position of the crane, the position of the main conductor line (side 1 or 2, see
sketch below) and whether the light barrier is to be self-monitoring or not must be
selected.
E.g.
• Crane1
• Main conductor line side 2
• 2-stage limit switch FORWARD
• Optical backward general
• Without self-monitoring
Special designs (turning of a crane, changing the side for operating the control pendant etc.) must be considered separately.
The following Y connectors are required for connecting the limit switches and/or
light barriers in the crane bridge enclosure:
• Y Connector X16 Part no. 719 863 45
• Y Connector X48 Part no. 719 864 45
8 Crane anti-collision device
42678944.eps
3
X48
3
1
2
21344
4
3
1
2
1
1X48.1
3
2
1
431
2
1
3
1
2
1
2
3
3
2
4
31
2
1)
X16
2
1
3
4
12
34
1
3
4
4
21
2)
1X16.1
2
1
3
1
2X16.1
3 4
2
1
3
1
2
1
2
3
3
2
1
3
4
2
42679644.eps
End of building I
Limit switch FORWARD
Fast
General
2-stage
without
Optical
BACKWARD
Fast
General
2-stage
Optical FORWARD
Fast
General
2-stage
without
Optical BACKWARD
Fast
General
2-stage
without
Optical FORWARD
Fast
General
2-stage
Limit switch BACKWARD
Fast
General
2-stage
without
Crane 1
Crane
side 2
Centre crane
Left
Crane 2
Right
Crane
side 1
End of building II
31
21491244.p65/201204
2
1
4
3
5
2
1
3
-X
2.1
-X
2
.2
The following cable modules are assembled according to the design variant:
Intermediate switch (different from the intermediate switches without anti-collision
device)
• Intermediate switch with connector designation 1X16.2 FIN BACK and
-2X48.2 Prelim BACK
• Intermediate switch with connector designation 2X16.2 FIN FORW and
-1X48.2 Prelim FORW
Light barrier
• Light barrier with connector designation –1X16.2 FIN BACK
• Light barrier with connector designation –1X16.2 FIN FORW
• Light barrier with connector designation –1X16.2 Prelim BACK
• Light barrier with connector designation –1X16.2 Prelim FORW
Additionally when connecting, a parameter must be set and a jumper must be
inserted depending on the design variant (see drawing below).
Jumpers (X16 and X48) are inserted in the board of the
crane bridge enclosure. Each cable module is equipped
with a jumper (suitable for forward and backward).
1X48.1
Forward
2X48.1
Backward
Cable with Y
connector
719 864 45
X48 – prelim / fast X16 - jumper
Parameter
E 020K08
Fast = 2
2X16.1
forward
1X16.1
backward
Cable with Y
connector
719 863 45
X16 - Fin / generalX48 - jumper
Parameter
E 020K08
General = 1
1X48.1
Forward
2X48.1
Backward
Cable with Y
connector
719 864 45
X48 – prelim / fast
Parameter
E 020K08
2-stage = 3
2X16.1
forward
1X16.1
backward
Cable with Y
connector
719 863 45
X16 - Fin / general
Fast
General
2-stage
42679244.eps
2
4
3
1
A
B1
B2
B
A2
A1
0
1
3
2
2
1
3
5
6
42679044.eps
42679144.eps
21491244.p65/201204
32
1X16.2
1X16.1
1)
2X16.1
1)
2
2
L4
X2.2 = L5
X48
1
1
X2.1 = L4
-X2
1
1
2
L5
L4
L5
3
2
4
3)
43
4
X16
1
3
2
4
21 43
3)
2
1
4
1X48.2
1X48.1
1
1
1
2
3
25
2X16.2
3
2
3
2
2)
5
4
2
1
1
3
2
3
21 3
2)
2
(L5)
(L4)
31
4
3
A14
A22A21
A13
1)
1)
X48
PE
31 4
31 4
2)
1
1
3
2
3
2
54 6
2X48.2
2X48.1
5
(L5)
(L4)
6
4
PE
2
1
3
B14
B22B21
B13
2
1
3
2)
-X2
21
1
2
3
4
5
3
2
1
2
5
5
34
4
1
2
5
4
3
1
X16
X48
48V~
Example for an optical 2-stage anti-collision device, see drawing page 30, crane 2, end of building II
Cable modules
Anti-collision device
Intermediate switch - Z 730 009 45
Light barrier - Z 730 010 45
Y connector - Z 719 862 45
Sockets on PCB
long travelling
Con-
nectors
Cable entry
Side wall
KRBG
Intermediate
switch
Light barrier
The individual switches, intermediate
switches or light barriers
must be assigned to connectors
X16 and X48
according to their function.
Prelim.
Backward
Prelim.
Backward
Fin. back-
ward
Fin. back-
ward
Fin.
forward
Fin.
forward
Prelim.
forward
Prelim.
forward
Control
voltage
48V AC on
terminal strip
Cable with plug
part no. 719 864 45
Cable with plug
part no. 719 863 45
wired acc. to
part no. 719 862 45
Light barrier
RLK 24-55-2466/100B
dark-switching
Visolux
part no. 466 922 44
Prelim.
forward
Fin.
for-
ward
Intermediate limit switch, type XCK-
MR1618668002
contact arrangement „washer F“
part no. 792 981 44
Contact block „B“
Prelim. Backward
Contact block „A“
PCB
long
travelling
Forward
Coding on pin 2
Coding on pin 3
End
42679344.eps
Fin. backward
33
21491244.p65/201204
9 Geared limit switch for the DR rope hoist
9.1 Geared limit switch
9.1.1 Determining the cut-out points
for the geared limit switch
The geared limit switch is fitted in the electrical equipment enclosure of the Demag
rope hoist.
It switches off the rope hoist when the top or bottom hook position is reached. The
direction of movement can be reversed. The emergency limit switch must not be
approached in normal operation.
Operating limit switches are required where the end positions are approached
regularly during normal operation.
In such cases, the switches must be adjusted so that the operating limit switch is
actuated first and then, i.e. if this fails to operate, the emergency limit switch.
Accident prevention regulations require that the crane operator checks the emergency limit switch before starting work. This can be done using the key-operated
button in the control pendant.
The operating limit switch can be by-passed by pressing this button. In order to
approach the emergency limit switch, the hoist unit must be switched on and the
check button pressed simultaneously.
The key-operated button must be pressed in order to leave the end position
(lowering).
The functions carried out by the geared limit switch can be seen in the wiring diagram provided.
The emergency limit switches must be properly adjusted to ensure prevention of
accidents and to avoid damaging the rope hoist. The emergency limit switches are
adjusted before leaving the factory to avoid complete unwinding of the rope, only.
Following installation of the rope hoist, they must be readjusted and checked for
the particular operating conditions.
If you wish to set the greatest possible lifting height for your specific operating
conditions, it is essential to observe the following:
The emergency limit switch for the top hook position must be set so that when it
switches off the lifting movement, the minimum distance between the top edge
of the bottom block and the bottom edge of the track girder is maintained (see
table 1).
21491244.p65/201204
34
F
E
C
The emergency limit switch for the bottom hook position must be set so that the
load hook does not touch the floor.
Setting the cut-out points is described in the setting instructions (section 6.2).
42679444.eps
Table 1 Limit switch cut-out point (setting dimension F) for the highest hook position, see fig. 11
Fig. 11
egnaRfopuorG
msinahcem
OSI/MEF
gniveeR mmnibhtdiwegnalF
002022042062082003023043063083004024
FE
orP-5RD
m3,m2
6M,5M
1/2
0115210
41551071581002034
1/4
0025710515210015709501021531051561143
m4
7M
1/2
022034
1/4
012143
moC-5RD
mA1
4M
1/4
002 571 051 521 001 57 09 501 021 531 051 561 143
egnaRfopuorG
msinahcem
OSI/MEF
gniveeR mmnibhtdiwegnalF
002022042062082003023043063083004024
FE
orP-3RD
m4,m3,m2
7M,6M,5M
1/
2
511031541061571581002714
1/4
58156154152150158001511031541061571803
moC-3RD
mA1
4M
1/4
581 561 541 521 501 58 001 511 031 541 061 571 803
egnaRfopuorG
msinahcem
OSI/MEF
gniveeR mmnibhtdiwegnalF
002022042062082003023043063083004024
FE
orP-01RD
m3,m2
6M,5M
1/2
04106
1071002022042062315
1/4
532012581061531011531061581012532062814
2/4
041061071002022042062824
m4
7M
1/2
041016
1/4
022135
2/4
0410610710020220420628
24
moC-01RD
mA1
4M
1/4 532 012 581 061 531 011 531 061 581 012 532 062 814
35
21491244.p65/201204
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!
Each contact is allocated to a cam disc which is infinitely adjustable.
The cam discs can be adjusted independently by means of the white adjusting
screws.
When turning the white adjusting screw clockwise, the cam disc is also turned
clockwise. 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 discs are designed in such a way that a max. useful path and a runon path are available.
The geared limit switch is already permanently connected with the control system
via the system connector cable. Move load hook of the rope hoist into the specified
cut-out position (cut-out points see section 9.1.1, table 1). 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.
The contacts are adjusted in blocks by means of the black adjusting screw. All cam
discs are adjusted together, while the relative adjustment of the individual contacts
remains unchanged. When turning the black adjusting screw clockwise, the cam
discs are also turned clockwise.
Approach cut-out points several times to check the limit switch functions are
operating correctly!
Adjusting screw, white
Adjusting screw, black
42589444.eps
For adjusting the geared limit switch, a hexagon socket key, 4 mm, is required.
9.2 Instructions for adjusting the geared limit
switch
Setting the contacts for individual
adjustment:
Setting the contacts for adjustment
in blocks:
Operating principle
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
Printed in Germany DZE/220205/1T
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