Operating instructions

DR 10 rope drum brake

Version: HB (holding brake)

42366144.eps

150306 EN / PDF 214 936 44 720 IS 813

 0 Foreword

You have purchased a Demag product.

This Demag rope hoist was manufactured in accordance with the applicable
European standards and regulations.
The rope hoist complies with the statutory regulations e.g. EC directive 98/37/EC.

These operating instructions contain additional information for operating these units.
They must be used together with the following operating instructions:
21493644.indd/150306

Accompanying documents
EKDR Pro rope hoist operating instructions 214 725 44 720 IS 813
EZDR Pro rope hoist operating instructions 214 691 44 720 IS 813
FDR Pro rope hoist operating instructions 214 932 44 720 IS 813
2
 1 General

Application The rope drum brake is an additional safety device for DR10 rope hoists which pre-
vents the load from dropping in the event of a failure in the drive chain from “motor to
rope drum”.
The rope drum brake only acts in the direction of lowering.

HB version The HB version (FB with extended functions), complies with the stipulations of the
Industrial Employers’ Mutual Insurance Association regarding a second brake.
In addition, it also fulfils the requirements of a safety brake according to the following
standards:
DIN EN 13135 –2: Cranes, equipment,
5.9. Additional requirements for handling molten masses

It can therefore be used whenever increased safety requirements are to be fulfilled

or measures against lowering of a load owing to impermissible rotations of the rope
drum in the lowering direction are stipulated.

When the hoist is switched off, the holding brake always is in the secured waiting
position.

For any required intervention during operation, the braking function can be tripped by
means of the emergency stop. Therefore, the holding brake fulfils the requirements of
an emergency stop brake.
The brake must only be tripped with the emergency stop switch in the event of a
hazard.
Application and operation of the rope drum brake are subject to the specific regula-
tions which have to be observed in the country concerned.

Work on the rope drum brake
For the functional reliability of the rope drum brake, it is of particular importance to
have the setting work performed exclusively by experienced technicians.
Experienced technicians are persons, who owing to their technical training and ex-
perience, have sufficient knowledge of winches, hoist units and towing equipment
BGV D8 and are familiar with the relevant national industrial regulations, directives
and generally accepted engineering standards enabling them to judge the safe
operating condition of winches, hoist units and towing equipment.
In addition, experienced technicians must have expert knowledge of inspection,
setting and assessing the rope drum brake.

Operating conditions
The rope drum brakes can be used at temperatures from +2 to +80°C.
In harsh environments, functioning of the rope drum brake must be ensured by fitting
a suitable enclosure to the actuating elements.
Rope drum brakes must not be fitted for hoists operated with load lifting
magnets.

Retrofitting Fitting of rope drum brakes at a later date must be agreed in detail with Demag.
For fitting the DR10 rope drum brake at a later date, special gear shafts, drums tubes
and drum flanges are required.
21493644.indd/150306

3
 1.2 Explanation of size designation/type assignment:

E K DR Pro 10 - 10 4/1 - 6 Z- 5/1 - 400 - 00 - 50 - 30 300 45 Remarks

Rail head width in mm only EZDR
or span
Flange width of the girder in mm
or girder section and size
Max. 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 10
Demag rope hoist
K = Low-headroom monorail hoist
Z = Double-rail crab
F = Stationary
E = Electric travel trolley

1) Code 01 EKDR with internal electrics for application on a crane. Crane bridge enclosure, DSE-8R or DSE-10R control pendant with control cable and cables
21493644.indd/150306

for the mobile floor control must be ordered separately.

Code 02 EKDR 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 or DSE-10R control pendant with control cable must be ordered separately.
Code 03 Like code 01 but control via a radio control system
Code 04 Like code 02 but control via a radio control system
4 Code 05 EKDR with fitted parallel interface “in”, not in connection with a holding brake.
 1.3 Selection table When a rope drum brake is used, the hook path is reduced compared with hoists
without a holding brake:
2/1 reeving: -1,7 m
4/2 reeving: -2,3 m
4/1 reeving: -0,8 m
6/1 reeving: -0,6 m

Range Group of mechanisms SWL Reeving Hook path Hoist speed [m/min]
FEM ISO [t] Drum [m] V1 1) V2 V3
H12 10,3

2m M5 5 H20 18,3

H40 38,3

H12 10,3
10 / 1,7
3m M6 4 2/1 H20 18,3 2 - 18 2 - 25
(12 / 2)
H40 38,3

H12 10,3

4m M7 3,2 H20 18,3

H40 38,3

H12 -

2m M5 5 H20 9,0

H40 22,9

H12 -
10 / 1,7
3m M6 4 4/2 H20 9,0 2 - 18 2 - 25
(12 / 2)
H40 22,9

H12 --

4m M7 3,2 H20 9,0

H40 22,9
DR 10
H12 5,2

2m M5 10 H20 9,2

H40 19,2

H12 5,2
5 / 0,8
3m M6 8 4/1 H20 9,2 1-9 1 - 12,5
(6 / 1)
H40 19,2

H12 5,2

4m M7 6,3 H20 9,2

H40 19,2

H12 -

2m M5 16 H20 6,1

H40 12,7

H12 -
2,7 / 0,4
3m M6 12,5 6/1 H20 6,1 0,7 - 6 -
(3,7 / 0,5)
H40 12,7

H12 -

4m M7 10 H20 6,1

H40 12,7
21493644.indd/150306

Note: For frequency-inverter-controlled hoists, the Pro-Hub function can only be used to a limited extent
in conjunction with the rope drum brake:
V2 to 1,2 x VNom
V3 to 1,0 x VNom
1) Values in brackets for 60 Hz
5
 2 Design and functional description

1 Connecting bolts
2 Dished washer pack
3 Brake ring halves
4 Pressure pring
5 Lifting magnet
6 Bearing pin
9 7 Pawl
8 Roller
9 Retaining plate
10 10 Limit switch

In catching posi-
tion, the plunger
of the limit switch When the brake torque has been set,
must still be able seal opening of dished washer with
to move a further Silicon 200 (part no. 000 403 44) up
1 mm. to the upper edge of the bolt head.

8 3 1 2
5

Spring positions
Pos. 3
4
Pos. 2
Pos. 1

42366244.eps

7
1

Dished washer layers as shown.

Spray dished washer pack and bolt
threads liberally with Gleitmo 582
spray lubricant, part no. 817 072 44.
Allow spray lubricant to dry before
fitting.

Dished washer layers

(2 x 6 dished washers)
3 mm

The tip of the pawl must be

inside the gearing circumfer-
21493644.indd/150306

ence of the brake ring.

18,6 ±0,7 100%

42318844.eps

Fig. 1 42366344.eps
6
 2.1 HB version The rope drum brake for the DR10 rope hoist is always designed as a safety and
holding brake. For every stop, the pawl is locked in the gearing circumference of the
brake ring by the hoist unit owing to the weight on the actuator.
The rope drum is thus secured against unwanted rotation.
When the hoist unit is switched on, an electromagnet of the actuator releases the
brake ring again.

These operations are timed so that in normal operation, the rope drum brake is not
used. It is only kept on stand-by.
If the pawl engages due to overrun of the rope drum (caused for example by weaken-
ing of the operating brake) the limit switch prevents any further lowering movement.
This condition is indicated to the user by one of the following indicators in the control
pendant.

Control pendant Display Remark

DSE 8/16 R B
DRC-10
Pawl engaged
DRC-J

DSE-10R

There is no additional optical or acoustic information.

The pawl is released again by switching on “lifting”.

Correct sequence control of the actuator in conjunction with the hoist unit motors
and the limit switch signal processing are provided by the manufacturer’s electrics.

2.2 Colour and position of Reev- Hoist Pole-changing motor Frequency-

ing speed controlled
pressure springs Part no. 50Hz 60Hz motor
Pos. of pressure 2 1 -
V1 704 106 45 spring
Colour blue 1) green 2) -
2/1 Pos. of pressure - - 1
4/1 V2 704 107 45 spring
4/2 Colour - - green 2)
Pos. of pressure - - 3
V3 704 108 45 spring
Colour - - green 2)
Pos. of pressure 2 2
V1 704 109 45 spring
Colour blue 1) blue 1)
6/1
Pos. of pressure - - 1
V2 704 107 45 spring
Colour - - green 2)

1) Pressure spring blue, art. no.: 342 354 44

2) Pressure spring green, art. no.: 342 316 44
21493644.indd/150306

7
 2.3 Function of the brake The rope drum brake is of the external shoe brake type, consisting of 2 brake ring
halves with ratchet teeth, the halves, held together by connecting bolts tightened to a
specified torque, grip the drum and rotate with it.
The asbestos-free brake linings are protected against ambient influences by rubber
seals.
The pawl pivots on a pin which is clamped between the retaining plates. The pawl
with roller is pulled against the cam wheel by a pressure spring until the tripping
speed is reached.
At a specific overspeed of the rope drum, the roller is raised off the cam wheel and
the pawl mashes into the teeth of the brake ring and stops it.
The still rotating drive flange with rope drum is gently braked to a standstill by the
pre-set brake torque of the brake ring.
At the same time, the pawl triggers the limit switch fitted to the frame, which switches
off the lowering motion.
This complete function is performed and ensured by the manufacturer’s hoist unit
electrics.
For the “control in steps” special design (parallel operating mode), this function is not
provided by the hoist unit electrics of the manufacturer. This function is not provided,
either in the case of set value specification which is not performed via the field bus/
CAN bus.

21493644.indd/150306

8
 3 Putting into operation

Hoist unit, rope drum brake and electrics are factory tested and no special inspection
test is required for putting the unit into operation. Only the electrical functions must
be checked by a specialist.

The rope drum brake is set, tested and sealed in the factory. The spring on the
pawl determines the catching speed of the brake and must not be tampered
with or exchanged with any other spring.

The holding brake may only be used in conjunction with an operating and emergency
limit switch for the upper hook position. It is then possible to lift the load hook by
by-passing the operating limit switch after the lifting process has been cut-out by the
operating limit switch and the pawl has been applied.

If the lifting process is cut-out by the (emergency) limit switch for lifting and the
pawl is applied at the same time, lifting of the load hook is no longer possible.
By carefully positioning the brake ring and setting the limit switch during installation,
this case is virtually excluded.
For automatic installations control must be arranged in such a way that the hoist
unit always briefly lifts the load hook before a lowering process is initiated. This en-
sures that a possible catching position is opened in any case.
The additional switching-on cycles must be taken into account for specification of the
motor.

Lowering into the catching position means malfunctioning of the installation.

4 Tripping the rope drum brake

Basically, there are three different causes for tripping of the rope drum brake:
I. Failure of the operating brake caused, for example:
– by non-observance of re-adjustment instructions,
– by excessive wear,
– by overheating,
or by accumulation of these causes in conjunction with loads in the range above
the rated load.
II. Breakage of one of the drive transmission components, e.g. gearbox, coupling or
shaft.
III. Damage to rope drum brake components. As a result of its intrinsic safety, the
brake is applied automatically whenever components of the rope drum brake do
not fulfil their function (e.g. damaged spring, stiffness of pawl bearings, loss of or
damage to the pawl roller).

In most cases the cause will be as described under I.

21493644.indd/150306

9
 5 Action required when the rope drum brake is applied
(lowering no longer possible)

Tripping of the rope drum brake is indicated to the user by an indicator on the control
pendant.

Control pendant Display Remark

DSE 8/16 R B
DRC-10
Pawl engaged
DRC-J

DSE-10R

The user should proceed as follows, in order to determine which of the causes men-
tioned in chapter 4 is the source of trouble:

Switch on lifting! 5.1. If the load is lifted normally and not held when the hoist motor is switched off,
the cause is I.
5.2. Check and repair the operating brake.
See operating instructions:

Document EN
EKDR Pro rope hoist operating 214 725 44
instructions
EZDR Pro rope hoist operating 214 691 44
instructions
FDR Pro rope hoist operating 214 932 44
instructions

5.3. If the load is not lifted, the cause is II. Have the hoist checked and repaired by a
specialist.
One or more of the drive transmission components of the hoist unit have failed.
The rope drum brake remains engaged and the “lowering” motion is blocked.
In this case, the load must be removed and the hoist unit checked and repaired
by a specialist.

21493644.indd/150306

10
 6 Electrical control for the HB version

6.1 Block diagram

PE

GL connector, Cable lengths

2 1

type 43001 Type DR 10 H12 - H20 DR 10 H40

Part number 719 163 45 719 164 45

14
22
13
21
Position button type TS235
TS 235-11z

Connector on -X34
1 1
2
2
Pinch off encoding pin 2
200mm

1 1
Pinch off encoding pin 1
2
2

100mm

Connector on -X37

Fig. 2 42371344.eps

6.2 Electrical control for

the HB version

6.2.1 Lifting When the Lift key is actuated, the actuator and lifting contactor K1 are switched on
simultaneously. The set value is created by actuating the lift/lower switch. In the case
of pole-changing motors, the set value switches lifting contactor K1 on, for frequen-
cy-controlled operation the set value switches the frequency inverter on.
As soon as the lift key is released, the lifting contactor drops without delay. The ac-
tuator remains switched on until the application time has expired.

6.2.2 Lowering When the Lower key is actuated, the actuator is switched on immediately while lifting
contactor K1 is switched on after expiration of the delay time. The actuator releases
the pawl during this delay.
As soon as the Lower key is released, lifting contactor K1 drops without delay. The
actuator remains switched on until the application time has expired.
The following sequence must be adhered to for braking operation in lowering
direction:
The main hoist brake must first bring the hoist to a standstill. The rope drum brake
pawl may then engage.
21493644.indd/150306

11
 6.2.3 Catching position When the pawl moves into catching position, the limit switch switches off the
lowering motion of the hoist unit. This condition is indicated on the control pendant:

Control pendant Display Remark

DSE 8/16 R B
DRC-10
Pawl engaged
DRC-J

DSE-10R

6.2.4 Deceleration time Due to the design, the required delay time is 0,5 sec.

6.2.5 Application time Based on typical manufacturer data, the required application time is 1,0 sec. Only in
exceptional cases, it must be calculated as follows:
Determine the braking time in the lowering direction with nominal load starting with
release of the Lower key until standstill of the load plus approx. 20 % of the time
determined this way.

21493644.indd/150306

12
 7 Maintenance

Maintenance work on Demag hoist units must not commence before the load has
been removed and the mains switch/isolator switched off. For the operation and
maintenance, the relevant accident prevention and other official regulations in force
in the country concerned must be strictly adhered to. Tests and checks required
in addition to those mentioned in chapter 8 must be carried out. Excerpts from the
accident prevention regulations are included in the test and inspection booklet for
Demag hoist units supplied with the unit. The rope drum requires little maintenance.
According to the relevant accident prevention regulations UVV BGV D8 § 23 (2)
or BGV D6 § 26 (1), the rope drum brake must be inspected by a specialist at
least once a year.
If required by specific environmental and operating conditions (e.g. multi-shift opera-
tion), it must also be checked by a specialist at more frequent intervals.
The following must be checked, repaired if necessary, and entered in the check list
(see page 19) at the specified intervals.
1. Ease of movement and condition of the pawl and roller
2. Any damage to the spring
3. Function and firm seating of the limit switch
4. Function and firm seating of the actuator (lifting magnet)
5. Slipping force

During the routine inspections, no catching tests should be carried out. Inspections
must only be carried out using the appropriate testing instrument (see chapter 10).
Every catching trial constitutes a short-term overload of the hoist unit sub-assemblies
and involves the hazard of premature failure of these sub-assemblies. The effective-
ness is guaranteed for the entire service life of the hoist unit when complying with the
above described inspection.

Setting values for rope drum brake: Table 1

Size FEM SWL 2/1 [t] SWL 2/1 [t] Slipping force Max. tightening
– Standard – Molten masses [kN] torque
[Nm]
2m 5,0 3,2 39 +2 42
DR10 3m 4,0 2,5 39 +2 42
+2
4m 3,2 2,0 39 42

Ordering parts Designation Consignment/specification Part no.

Chain grease Gleitmo 582 400 ml spray can 817 072 44
Loctite 290 50 ml bottle 007 275 84
Silicon 200 310 ml kit 000 403 44
Tachometer 822 088 44
Cable 3 x 0,75 mm2 H05VV-F3G 471 162 99
Cable strap 8/33 472 778 44
21493644.indd/150306

13
 8 Setting and testing

In order to ensure that the testing instrument

is fitted correctly, bolt (2) must be screwed
fully into the hook thread (3). Testing 2 3 2nd 1 Joint
instrument tooth
For setting, the lifting mag-
net (item 5, fig. 1) must be
removed.

Lowering direction

Fig. 3 1 42366444.eps

Adjusting

21493644.indd/150306

Fig. 4 42366544.eps

14
 1. Remove lifting magnet (fig. 1, item 5). In order to test the slipping force, the testing
instrument must be inserted in the direction of lowering and hooked firmly onto
the second tooth behind the joint (see fig. 3). Switch on the motor in the lowering
direction, read slipping force from measuring instrument.
The slipping force must be within the setting values given in table 1 (see page 13).
For this procedure, the hoist unit should be operated with a load on the hook (at
least 0,5 x SWL) so that the full force does not have to be supplied by the drive
alone.

The motor must not be switched on for more than 5 seconds because of the
temperature increase.

1. If the testing instrument does not indicate the correct slipping force, tighten con-
necting bolts (1) alternately and evenly until the measured value (see table 1,
page 13) is in the prescribed range. The maximum tightening torque of connecting
bolts (1) must not be exceeded.
If the set value (see table 1, page 13) is not reached, the rope drum brake must be
repaired by a specialist from Demag.
When the rope drum brake has been set, seal the connecting bolts on the brake
ring with Roccasol Silicon 200.

2. The correct position of the limit switch is such that when the pawl is engaged, the
limit switch is actuated and its plunger can still move approx. a further 1 mm (see
fig. 1, page 6). This setting must be obtained at 3 points around the circumference
of the brake ring.

3. The actuator on type HB is fitted so that the tip of the pawl projects at least 3 mm
inside the circle of the brake ring when the magnet is de-energized (roller on cam
of cam disk, see fig. 1, page 6). This position is only possible when the pawl tip is
between the brake ring teeth.

During a general overhaul of the hoist unit, a general overhaul of the rope drum
brake must also be carried out.
This work may only be carried out by specifically trained experienced
technicians. The work may only be carried out by the manufacturer or
companies authorized by the manufacturer.
21493644.indd/150306

15
 9 Testing instrument

Testing instrument: part no. 704 670 45

2
5

31

320

Fig. 5 42366044.eps

Item Quantity Designation Type Part no.

1 1 Hexagon bolt ISO - 4014 - M12x215 8.8 - A2F 150 508 99

2 1 Pivot bearing ISO 12240 - 15/42x15 GE 15AW 452 686 99

3 1 Hook, testing instrument DR10 DR10 704 671 45
4 1 Pressure gauge DR10 704 672 45
5 1 Manometer 0 - 60 kN 822 076 44
21493644.indd/150306

16
 10 Tools

Torque wrench
(we recommend using a wrench with analogue display)
Measuring range 20 – 120 Nm
with 1/2" square drive
Adapter 1/2" inner to 3/8" outer (12,5 x 10)

Extension 3/8" 160 mm long

Adapter 3/8" inner to 1/2" outer (10 x 12,5)

1/2" drive for socket-head screw (DIN 6912) with pilot, SW 8

Fig. 6 40148644.eps

Required tools and accessories

Item Designation Part no.

1 Torque wrench -
2 Testing instrument 704 670 45

3 Brake release attachment 1) -

4 Hand-held tachometer -
5 Benzine 100/140, 1 l bottle 342 681 44
Acetone varnish remover (from 30 l barrel) 022 919 84
6 Gleitmo 582, 400 ml spray can 817 072 44
7 Silicon 200 sealing compound, transparent 864 044 47
Silicon A+B sealing compound, 4 kg bucket 891 306 44
8 Loctite 290, 50 ml bottle 007 275 84
9 Sealing wax -
10 Depth gauge for checking the contour ring (small tolerances) 670 090 46
21493644.indd/150306

1) not required for DR 10 with ZB motor

17
 11 Check list

Owner: _____________________________________________________________________

Where in use: _____________________________________________________________________

Size DR: ______________________________________________________________________

Holding brake

Rope drum brake: HB

Serial number: ___________________________________________________________________

Main hoist motor: ___________________________________________________________________

Lifting speed V2/1: __________________________________________________________________

Gearbox transmission ratio i: __________________________________________________________

1 File test report (original) in the DH hoist unit or crane test inspection booklet.
2 Send duplicate test report to Demag Cranes & Components GmbH, Quality Assurance
Dept. 2221.

Braking force
Set Required 1) Date Signature
Slipping force kN kN
Tightening torque of connect- Max. perm.
ing bolt (1) Nm Nm

Catching speed
Operation Measured values Calculated values Required Colour code 2) Date Signature
V2/1 V2/1 = 1,3 x Vact of spring
[rpm] [m/min] [m/min] (Item 4, fig. 1)
Catching

Lowering
21493644.indd/150306

1) See table 1, chapter 7

18 2) See section 2.2
21493644.indd/150306

Notes

19
 Printed in Germany PDF 150306

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.